1994 Husaberg Rebuild - Big Mistake

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Joined
Apr 16, 2016
Messages
15
Location
Iowa
Hey everyone,

I finished up my rebuild on my 1994 501. The bike started up on the first or second kick and ran great in the 10 minutes I had it out. That's the good news. The bad news is that I found a clip laying on the table that I am about 95% sure that it is a piston circlip :cry: I'm not sure how I made this mistake - I could have sworn I put both clips in, but I was working in dim lighting and had to remove my piston once after a ring slipped out of the ring compressor. I must have forgotten to put one of the clips back in.

This is just wishful thinking, but does a clip like this happen to go somewhere else, such as on a gear spline?

Since I understand I will likely be tearing the engine apart, do any of you have a recommended method that I can get to the piston with minimal disassembly?

I guess I learned a valuable lesson to take my time and double check myself in the future.
 
Can't get my picture to upload, but it looks just like the piston circlip. I can't imagine a clip like this would be used on anything else.
 
You didn't put new clips in? and your looking at one of the old ones? Or reinstall an OLD clip and you are looking at a new one?


Sent from my iPhone using Tapatalk
 
I was in a hurry assembling an engine once. Got my '95 501 all together, fired it up, and it ran like a champ. Rode 15 miles to work the next morning and smelled coolant when I got there. I took a quick look at the engine and saw a touch of wetness at the head gasket. Then I thought about it all day at work and wondered if I had forgotten to torque the head bolts. Now here's where my judgement is in question...I rode it home (another 15 miles) before checking the 2 nuts that are accessible from the outside. Sure enough, they were finger tight! Pulled the rocker cover off, torqued everything down, put it all back together, and she ran like a champ again.

Do yourself a favor and take it apart to check. You don't have the pull the cylinder all the way off the piston to see if there's a wrist pin clip missing.
 
i wouldn't say there's any clip like the piston clip. nearly every other clip ever in a husaberg has been a squared off clip and not circular wire.

so a piston clip it is.

I would just get it to TDC, undo the split link, head off, barrel off.

regards

Taffy
 
Thanks for the input. The good news is that atleast I know that when I get it back together, it will be running good. At least I caught my mistake before I ruined a cylinder.
 

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