07 v08 v\09

I was told the 08's have roller bearings where the 07's have needle bearings. I have heard year after year one is better than the other. what does it all mean. I also heard from some that some of the bikes are almost bound to have main bearing problems. I heard the fix was to ensure the float was set right.... but orangeberg says despite that they have TOO many bikes in the shop.

Is the old 07 or 08 motor reliable as any ktm say..... or is it really a matter of waiting for the 09??

Out of the old motors which size is the most reliable ..... I heard the 650's give little trouble but the others have main bearing problems no matter what?

any comments

Some on this site have had trouble with main bearing failures, but, I believe those kinds of failures are in the minority.

The most common problem is a weeping water pump seal.

Cheeseberger just iron manned the Baja 1000 this year, 1320 miles, on an 05 FE550E with no mechanical issues what so ever. Cheeseberger also has an 04 550 with some 5 or 6 thousand miles on it, with mid 300 hours and has had only to replace a cam chain.

I have an 04 550 with 3500 miles and almost 200 hours and have had to replace a water pump seal.

Dirt Rider magazine here in the states did a long haul or endurance test on a 2006 FE650 put several thousand miles, and well in excess of 200 hours on it with no main bearing failures, or major failures of any kind. They did have to replace a few plastic parts, and a couple of water pump seals. After tearing the motor completely down the found all tolerances within spec, threw in a new piston and rings although the original were still within spec, and put the bike back together. There are not many dirt bikes out there that have that kind of durability.

And to answer your question directly, yes there were some main bearing failures on the roller bearing shod cranks of the early 650's that I believe were traced to two contributing factors. The end float was set too small, and in some instances on the FS or Motard bikes it was believed that the crank was flexing a bit causing the roller bearings to break the edge off of the inner race of the bearing causing a catastrophic failure. However, that issue has not been around for some time. Use the search engine here on this site to find those related threads.

I believe the 07's had some increased webbing in the crank area of the 550's to help support the main bearings.

As far as the 09's go, it is my understanding that they are flogging the prototypes regularly trying to flesh out any reliability problems.

Hope this helps,

I've followed the evolution of these bikes closely and am a long time Husaberg fan. Other than 01 and 02, Husabergs are reliable bikes. 01 was a year of a complete redesign with a new balancer design. Took a bit to sort things out. 04 was the year ignitions and carbs went Japanese. 05 added an oil jet for the balancer auxillary drive shaft. I believe it was 05 that the 650 had a reduced stroke to beef up the crank. Is now a 628 rather than a 644. Japanese ignition had first year problems that were sorted in 05. New headpipes that didn't rub the front tire were introduced for 05. The poster on my wall shows beefed cases in 07. 05 up Husabergs don't require any more than a KTM to enjoy. Just open the crate and enjoy if properly maintained. MY 03 Husaberg 501 has 60 Hours and 1200 miles. Has been a reliable bike and still use it regularly for dual sport rides. I also have an 06 450EXC KTM. It has been totally reliable. Was unsure about the Bergs with all the failures of the older ones still in the limelight, but 2 years later, I have to say that an 06 Husaberg would have been a fine choice. Time tells the tale.
dan
On the main bearing topic. Unless you are a top level motard rider, it doesn't seem to be much of a problem on the newer bikes.

333 engine hours and 8500 miles on my 05 FS650E.

Engine problems to date...

Crunchy rolling action on the rocker arm roller bearings. Replaced rocker arms.

One broken exhaust valve spring causing no other damage to the motor.

Some preventative bits and bobs have been replaced along the way while the motor was down for other maintenance. Updated counter balancer, new piston & rings, new cylinder barrel, new valve springs, new main bearings.

I've been satisfied with the reliability of my bike. Easy to service when service is needed.

On the main bearing topic. Unless you are a top level motard rider, it doesn't seem to be much of a problem on the newer bikes.[/quote]
Hi Dan

Regarding the main bearing failure, talking about the problem with Alex DCR he said a lot of the problems occured when the engine was at idle, braking the flange off the inner race.
This is what brought around there crank modification.

Regards

Sparks.

After a 27 page topic on mains with the finger pointed towards the fast motard guys overstressing things, one of the top guys says the flanges were breaking off at idle. What a twist of fate. Did he give you any detail as to what was going on that caused the breakage? What modification was done to stop it.
thanks in advance
dan
Looking at the 08 Factory Husaberg site, they tell of improved crankshaft tolerences for increased reliability, new waterpump seal arrangement, and a new one piece counterbalancer with new bearings. Darn, was falling behind by not reading the 08 news.

thanks that provides a level of confidence to buy some left over 07's..... or 08, the last of a run can be a reliable bike and sit back and watch the 09.

well i didn't want to spoil your party dan but it was a bit more complicated than elite SM riders?

anyway, thats for another thread...

regards

Taffy

Much more complicated indeed, it's just that the only thing anyone could agree with was that it happened mostly to the guys on tarmac. I anxiously await a reply from sparks. By the way, how do you like working for Beta by now? I enjoyed your technical article explaining the differnces between the Berg and Beta motors.
dan

hi dan

yeh that was a short lived thread and the link to husaberg is teuios i knoiw but i thought that the petrolheads might get it!

it's actually sherco i'm working for and i have a 450i in bits.

looking around the beta which is a 250, i felt that it possibly has even more in common with the husaberg than the sherco does!

however i haven't had the chance to get in one yet. the beta 250 has a dreadful flat spot in the power curve and you have to treat it like a 2T to get it going. i wqas thinking of getting my jetting hands going but what is the point? it'll be done in my time and to no benifit.

regards

Taffy

Ah yes, it was Sherco. My wife always asks if I want her to listen to what I say or what I mean. Do remember Froggy cheering about them being made in France. Would have sworn they were from the Spanish area of Catalonia where Bultaco once existed. Seems as if the trials bikes are built there and the Enduro models in France? Anyway, the 450 and 501 motors resemble the new for 08 KTM SOHC 4 strokes and the 250 resembles the DOHC version from those pesty Austrians. Are you going to start riding one of the Shercos soon?
dan
P.S. 3T trials is a neat bike and I hear it won the Brit championship.

Hi Dan,
Yes you are correct they manufacture the 250 and 290 2T here in Spain it's the 450i that is made up in France.
I have also sent you a PM don't think you have seen it.

Regards

Sparks.

i hope to ride one for fun but i don't expect to be given one! i expect to ride my own bike mostly. the enduros are in nimes, france and trials in spain. i'm told the french are impossible(R)!!!!!!!

we'll see!

if i was to fettle anything it would be the 250 i hope.

regards

Taffy

Hello guys,just one question.When the water pump seal need replacement?Do you suggest some our limit for replace?Sorry for my English

regards

Sotos FS 650e '07 model

english is ok.

i believe that when you have a good seal you should leave it. obviously once per year or in my case: three seasons is ok.

regards

Taffy

I see,so it is early for my 43 hours engine.Thanks Taffy

regards

Sotos FS 650e '07 model