02 FE 501 Engine re-build step by step blog.

arkley123 · Apr 21, 2014

Ok Guys (& Girls),

02 FE 501 Engine re-build step by step blog.

It is what it says on the tin & as a result of this thread. (Cheers Logjump / Zaga / Ned / Big Berg / Tourist & Makazica).

http://husaberg.org/mechanical/17557-501-cam-lobe-completely-worn-away.html

I’m not going to put a time-frame on this as I have other pressing commitments / Wife / Kids / Work etc. but.... (& Makazica already mentioned £750.00 & 8 months which sound awful but is probably spot on!!)

1/ Any idea in hours how long it may take.
2/ Any tips before I start.
3/ Should I (with the aid of the workshop manual) just pull the whole thing apart – every moving piece & build from ground up (replacing as I go).
4/ Will it back together before my 14yr old moves up to 125 sized bikes (did a couple of laps on the Berg as pic below but still a bit big & heavy).

Hoping Taffy may assist as he's my mate and local but has been significantly quiet on this topic. Maybe sulking as I haven't been out with him for while.

Cheers in advance.

tourist · Apr 21, 2014

Best of luck! remember to have fun with it

And I for one can say it straight out that I'll enjoy the privilege of getting to think stuff through with ya if/when the process gets tricky! as with all the spannering on here.

such a nice site! thanks all!

zaga · Apr 21, 2014

Hi

First let me say that doing that kind of job for me it's a lot of fun, it can be a bit stressful sometimes, but it's a lot of fun.

Second, I don't think that you are looking at that kind of costs, unless you have something very wrong, it should be much cheaper.

Third, I don't know the shipping costs, but I can do it for you a complete refresh of the engine, with all new bearings, seals, timing chain, etc, a lot cheaper then that.

Fourth, as I've told you, I can provide you with lots of cheap parts for that engine.

Fifth, tell us what tools do you have in your garage and what kind of experience do you have.

Good luck
Cheers
ZAGA

logjump · Apr 21, 2014

Cheers arkley123!
Now I don't feel quite so bad for not mentioning a few critical steps prior to de-burring your shift mechanism. :ninja:

Looks like you've got quite a project in front of you. With your attention to detail in your woodworking career, there's no doubt you can pull off a rebuild!
I think it's really cool that you're gonna blog this happy experience so I can watch and learn too. :headbang:

:stop::stop::stop: Something I haven't seen here for a while or may have missed, is the fact that 01' thru 03' engine cases were susceptible to cracking near the swingarm pivot on the drive chain side. This happened with my 02' 501, so I hope you really check that out before getting too involved. I paid dearly to have mine welded only to have it fail again. Trying to save you some Husa-grief.

log

.

ned37 · Apr 21, 2014

one tip i can give is: if and when the cases are apart, disassemble and clean out the oil bypass mechanism. you can't get to it from the outside like the newer ones.

zaga · Apr 21, 2014

logjump said:
:stop::stop::stop: Something I haven't seen here for a while or may have missed, is the fact that 01' thru 03' engine cases were susceptible to cracking near the swingarm pivot on the drive chain side. This happened with my 02' 501, so I hope you really check that out before getting too involved. I paid dearly to have mine welded only to have it fail again. Trying to save you some Husa-grief.

log

.

That is very true, except for one 501 casing that I have here now, I've never seen another without cracks, even if they are micro.
Some time ago Taffy sent me 2 or 3 sets of casings to replace mine and they all were like that, I've rebuild one 470 for a friend, also like that.

My advice is to check the machined face were the cases touch and see if there is some kind of gap, I've corrected that with success, and also I stoped doing that stupid torque they recommend on the swingarm pivot.

Cheers
ZAGA

arkley123 · Dec 22, 2014

Oh Well..8 months on & haven't even started yet. Poor old Berg sitting in the shed undercover...think its the end of the road to be honest as I just don't have the time or inclination at the moment - teenage kids etc...going to put a post in classified here & ebay. Be great if I could sell as a fixer upper but I feel I'll get more cash if I part it!! It was a great bike & Taffy did some great mods on it.

Taffy · Dec 23, 2014

first time I've seen this thread, sorry to hear that James. don't know what you can do.

all i would do is bring the head here and let me recon the head.

then you fit the head.

or I buy the bike?

Taffy

arkley123 · Dec 26, 2014

Hey Taffy - hope you had / having a great Christmas.

Dilemma is I reckon the engine ready for a complete re-build - mains etc & this is too much time & money for me at this time.

You see 02 501's going as runners for £1,500.00 here so how can I charge that for a non-runner.

I've totted up the bits if I break the bike & that comes to about £3,000.00 even if I don't part the engine.

Obviously I wouldn't get that much as you don't sell everything & how long do I want to keep the skeleton of a part parted bike, but that said I reckon I could get £1,500.00 - £2,000.00 in bits.

Don't want to break it but...haven't done the ebay ad yet.

Taffy · Dec 27, 2014

where did you get £3,000 from?

I'd have put it as nearer £1,000 and £1,500 tops for real cash in the hand. the negine would be 200-400 and the wheels sell well but the rest just doesn't move.

having said that, you'll sell what you never thought you would and be stuck with something you thought would sail out the door.....

regards

Taffy

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