02/03 FE400 Punched a hole in the head and rocker cover

dmac_berg_rider · Jan 9, 2015

So a bit of back story before I get into it I was having major problems with the bike fouling plugs within minutes, so I decide I'd take the plunge and change to the FCR ditching the problematic dellorto, had troubles with the switch but finally had it running and running well with the FCR. About 10 minutes into test riding it around the streets a loud noise began and the result is as follows in the pictures.

We think something got caught on the inside of the cam chain and punched a hole through the rocker cover and through the head was wondering what could have done it and could I have prevented it. The bike lives very well and has an oil change and a valve clearance after every second ride and oil filter done after every four. Please Help any advice on what the cam chain guide should look like and where to source parts for the fix would be appreciated.

berglsmerg · Jan 9, 2015

That is some nasty **** bro. That chain guide is usually 1 piece, and has been superseded by a black one. If its an internally stock motor there qre some tasty upgrades to be had.

You want to talk to the Aussie berg guru. http://husaberg.org/husaberg/17970-orangeberg-back-workshop.html

tourist · Jan 9, 2015

:O sorry to see that

... fwiw I'd think that the rocker cover itself could be welded up, at least w.r.t. metallurgy and welding, can anyone confirm or disprove? Would it warp the head maybe?

Kayeffess · Jan 9, 2015

It looks like those are the guides from both sides.... The blade type is from the back side of the chain. I think the other one is the guide from the front side. Could it have come loose and travelled with the chain up into the sprocket and punched the top out of the cover. Did it tear the bolt out at the top of the head. The one that holds the tensioner blade?

Edit. Looking at photos, it looks like it messed up the cam tensioner blade bolt/hole and maybe even bent some of the casting of the head.

Mine did that when the cam chain broke... Didn't break the cover though.

Sorry

bushmechanic · Jan 9, 2015

usually when a pic like that is posted the owner finds one of the valve lash adjustment locknuts missing or they find an extra one from a previous owner has done the damage

the alloy welds easy I bolted mine to a 2" thick cast iron plate to stop it warping

the good parts suppliers are listed in my signature

dmac_berg_rider · Jan 9, 2015

Thanks for the quick reply, no lock nut was missing and there wasn't an extra one. Can anyone tell if there is a bit missing off the cam guide?

edelweiss · Jan 10, 2015

I would say the chain was loose and jumped on teeth. maybe the chainguide was not fastened properly, got loose, not in line with the chain and interferred. buy a new cam chain and compare its lenght to the current one (if you think you dont need a new chain, ask someone to measure new chain for you and compare to yours lenght). I would split the cases and check/change main bearings and both bearings on water pump shaft and counterbalancer bearings, on camshaft also. check the sprockets and change the chain guides to the black ones (if you order for 450 my2006 you cant go wrong). if there is an axial play on the camshaft (has space more than 1mm to travel from left to right), put some washer/s behind the bearings to limit the play and tocenter the upper sprocket to be in line with the one on bottom.

Taffy · Jan 10, 2015

if all the adjustment nuts are there then it will probably be the stop bolt for the auto decomp. have a look at where the ADC swings out to and either there is an M4 allen screw and nut there or a hole.

when you get the left cover off you'll see it laying in the bottom of the engine in the oil.

I do a modified later blade for about $15AUS.

as for the cover - very weldable and also a kind of 'good scar' to have when it is all done. just bolt it down to the head or a large strong plate and weld a strip of alloy in.

I can supply all the parts from stock you'll need fella.

regards

Taffy

berglsmerg · Jan 10, 2015

berglsmerg said:
That is some nasty **** bro. That chain guide is usually 1 piece, and has been superseded by a black one. If its an internally stock motor there qre some tasty upgrades to be had.

You want to talk to the Aussie berg guru. http://husaberg.org/husaberg/17970-orangeberg-back-workshop.html

Should look at the pics more carefully, duh

Taffy · Jan 10, 2015

you'll need the head welding up as well. when I do these I scribe a vertical and horizontal line to the side. then have the hole and the crack welded up and then using the two lines I know where the hole used to be and drill again.

be careful and try not to weld the mating surfaces as this draws the aluminium down and then you'll have a gap twixt head and rocker cover....not good.

regards

Taffy

dmac_berg_rider · Jan 12, 2015

Cheers for the support guys, the auto decomp bolt is there so, thinking like said above the cam chain stretched enough to grab the guide which probably went brittle and dragged it up into the rocker cover. Found a picture of a guide from a 99 husaberg that shows three reinforcements horizontally what's left of mine only has 2 can anyone tell me if 02/03 fe400 should have 3?

Taffy · Jan 12, 2015

that won't have happened.

think again mate.

the probable cuase is still out there...

Taffy

dmac_berg_rider · Jan 13, 2015

Everything else seems to be there and pulled off the left hand cover didn't find anything, and the top of the guide is the only rough part on the guide every other edge is fairly smooth

bushmechanic · Jan 13, 2015

there's a pic in this thread somewhere of what i did to fit the newer guide

http://husaberg.org/mechanical/17998-bushmechanic-mongrel-628-trailbike.html

the pivot is located closer to the rear of the bike with the newer guide

02/03 FE400 Punched a hole in the head and rocker cover

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