04’ husaberg 650 headgasket issue

Sorensen · May 23, 2021

Hello!

Upgraded my top end with new valve springs etc, now I’m trying to fit the new head gasket, but every time I try the gasket leaks water out the exhaust and in the engine case, can’t find any issues with the top or bottom, no cracks or anything, old and new gasket are the same too.
Bike ran fine without any leaks before I removed it.

Anyone has any opinions on this? Is there something I’m
Missing?

Thanks

Taffy · May 23, 2021

I'm worried for you because it might just be that the liner has cracked.

you need to remove the cylinder head and look 8mm down the bore for a hairline croack running around the bore 8mm from the top.

I really hope not.

PM me regarding HGs.

cheers

Taffy

Sorensen · May 24, 2021

Liner is fu»»»ed

Found a crack all around..

Bike ran fine before this, what could cause it and whats my options now?

Taffy · May 24, 2021

Nobody really knows. so you are saying that you never split the engine, you just took the head off? this is the first time I've heard of this? normally, mechanics have split the engine and this means; "what did they touch?"

not you though. https://www.facebook.com/178567042268291/videos/791027014355621

have a look at this video.

cheers

Taffy

Sorensen · May 24, 2021

Just took off the top, mounted new springs etc, mounted back on and water seeped trough

Bike ran fine previous season with no signs of water, changed oil every 10 hours so I would’ve noticed..

So new liner and piston then

jojo09 · May 25, 2021

Which head gasket did you use?

jojo09 · May 25, 2021

If you didn't use OEM... Go on reading the forums on FB.
Lots of cracked liners.

Taffy · May 25, 2021

jojo09 said:
If you didn't use OEM... Go on reading the forums on FB.
Lots of cracked liners.

Oh really!

well, I go on the Swedish and the Australian Husaberg forums and don't see lots. I have customers contact me who don't use forums with 450 2004s but rarely anything else. This is the first I've seen without the engine being split which tells me a lot.

what does it tell you?

Taffy

Alfy · May 26, 2021

Could loosening the head bolts completely 1 at a time rather than gradually all 4 together create a break in the liner?

jojo09 · May 26, 2021

Why should loosening the bolts create a crack?
It's the torque when mounting the head that cracks the liner.

Alfy · May 26, 2021

Sorry if you mount the head by tightening the bolts 1 at a time to the maximum tightening, don't you risk cracking the linar? If so, don't you create the same dangerous situation when you loosen the bolts 1 at a time? If you don't loosen the bolts a little bit at a time and all together here is what happens: you loosen the first bolt while the other three are at maximum tightening, loosen the second bolt and the remaining 2 are at maximum tightening, loosen the third bolt and you have 1 bolt tightened at maximum tightening which creates abnormal tension on the liner surface ...
Ps i love my husaberg ��

jojo09 · May 26, 2021

Alfy said:
Taffy if you mount the head by tightening the bolts 1 at a time to the maximum tightening, don't you risk cracking the linar? If so, don't you create the same dangerous situation when you loosen the bolts 1 at a time? If you don't loosen the bolts a little bit at a time and all together here is what happens: you loosen the first bolt while the other three are at maximum tightening, loosen the second bolt and the remaining 2 are at maximum tightening, loosen the third bolt and you have 1 bolt tightened at maximum tightening which creates abnormal tension on the liner surface ...
Ps i love my husaberg ��

If this really was a problem a lot of `normal` users with little knowledge would be destroying their liners.
Also...shouldn´t it be listed somewhere in the Workshop Manual?

It only says:
Loosen the 4 cylinder head bolts crosswise and remove with the washers...

No offense.

Taffy · May 26, 2021

Hi it sounds feasable Alfy.

fact is, the inside ledge is not perfectly flat in some engine crankcases. I've had a customer ask for money offf if he got an engineers report and shared it with me.

'fair enough' I thought. so he had an engineer look at it and I expected him to agree with me about my video but he didn't. The engineer said that the ledge has a very sharp 90d corner but there is a radius under the liner shoulder. the liner therefore can't get sll the flat part down on the ledge.

imagine one soup bowl inside another, they can rock and slide, they don't sit on the bottom oof the soup bowl underneath.

Let us remember also that 95% of the trouble has been with 450s from 2004.

Its nothing to do with head gaskets this one.

attached are ideas. I had a tool made that you drop into the top and if you see a rod below the round disc well in the hole in the rod goes a dial gause. the disc diameter is only 0.1mm smaller than the hole for the liner. .

Taffy

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04’ husaberg 650 headgasket issue

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