2003 FE501 rebuild

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kli

Joined
Feb 25, 2011
Messages
164
Location
Pazin, Croatia
Hi all,

Almost two mounts ago I started with rebuild of my FE501.

Everything started with exchange of timing chain, upgrade to newer blade, upgrade of decompresor, sprague and starter clutch.

When I take engine out of I realize that it take me hour more to strip down complete bike, so I decide to paint it.

After removing rocker cover I saw that follower bearing, bushes on axle and tappets are damaged, detailed in this post: http://husaberg.org/mechanical/18176-cam-follower-bearing-2003-a.html

I own the bike for cca 60 hours, so after situation with rockers I decided to remove cilinder head to check what is with valves, cilinder, piston etc.
Put some gasoline in head, exhaust were leaking.
Pulled down everything, inlet valves were damaged, one inlet seat broken, exhaust can go, on guides can be felt small amount of play.
Decided to put all new stuff and make upgrade to DVSK, detailed in this post: http://husaberg.org/mechanical/18340-fe501-top-end-refresment.html

Both brake pads, and disk were at the end, so decided to change them also, put Galfer from KTM.

Also put new sprockets and chain.

Enjoy in pictures.
BR
Goran
 
Last ride

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Stripping it down

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Stripped, part all over the garage :D

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Damaged head, leaking exhausts, damaged inlets and one inlet set broken.

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Cylinder and liner looks fine.

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Hi Tourist,

Unfortunately it's still in peaces.
Hopefully I think it will be done in next two weeks, I don't have too much free time to play with it.
 
Ahh, misunderstood, haha ... job well done!!!, sorry about that ... Good luck anyway!

How long is the riding season over there? Year round?
 
From september to may/june.

Normally in september temperature drops around 20 °C, during winter it's mostly above 0 °C during day.

This summer was special, it was lot of rain and temperatures around 20-30°C so it was all year season. Normally it's around 40°C.
 
Sandblasted frame, stored in dry place :D , wife almost kicked me out together with frame :D:D:D

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Two component epoxy primer, 3 layers.

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Waterborne paint and anti scratch lacquer
Paint is Subaru "Adriatic blue effect" code Z7B, looks very nice.

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Yellow hubs and other details.
I was thinking to go with RAL 1016 for yellow, but car refinish workshop where I buy paints have paint scanner, so he scanned front fender (newest yellow part on my bike) and mixed exactly the same paint.

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Hi kli,
That's a very serious restoration you're doing, and a nice one to:cool:
As for women they don't appreciate "modern Husaberg art " at home:D:D
Hoping for a speedy rebuid!

Grtz Rens

p.s.about that kind of art and womens reaction in this,i am an exlert by experience:D:D
 
After almost month of pause I started again to work on baby.
Machine is finished, it's time to put back everything in frame :)

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Polishing exhaust

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Jako, jako lijepo.
Zelis mozda jedan stitnik lanca? Imam viska, a imam i plavi rep i jos neke sitnice.

Obzirom na tvoj trud dio stvari bi i poklonio....

M.
 
Protecting old SEM from rust.
I used spray enamel, we used it normally on work for smaller repairs of electrical motors.
It's class F, meaning can stand up to 155°C and have dielectric insulation of 1800 volts per millimeter.

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