501 Cam Lobe Completely Worn Away

arkley123 · Apr 20, 2014

OK, so if you’ve been following the thread below you’ll know that after a small crash at local mx track on my trusty FE 501 02, the shift rail & shift quadrant plates got jammed (don’t think it was as a result of the crash directly).

http://husaberg.org/mechanical/15529-1998-600-stuck-second-gear-2.html#post147421

Anyway, other than that, bike been running fine.

As a result of being a **** & fiddling with all the cogs I felt the need to have the rocker cover off to check the timing positions...

At first I thought there were 2 types of rocker roller bearings – a flat type & a radiused type & that the radiused type has chipped away the female wall edges in the cam shaft lobe...(I did say **** didn’t I??).

Have you ever seen this much wear on a running engine before??

Had noticed a small (really) amount of sliver coloured filings last oil change but nothing to get too excited about.

I guess the big question is; as an 02 – 14 year old motor, if I’m going to replace the cam, what else should I do at the same time.... I’ve kind of been thinking the mains are due for a change but this is all getting a bit major & perhaps a refurbed engine would be a better way to go??

Or...better the devil you know...

zaga · Apr 20, 2014

Hi

One thing is to change the cam, other is to strip it all the way ... do you any experience on that ??

As I told you before I have a perfect 501-02, but I don't think that changing the all engine would be the way to go, not for me ... But I would be more than happy to sell you mine !!

If you have some experience I think you should check it all, mains, cranck, piston ... If you don't, probably would be better to get some help.

If you need anything let me know.

PS: I have a perfect cam for you

Cheers
ZAGA

arkley123 · Apr 20, 2014

Cheers Zaga - meant to PM you after our last discussion.
Experience - umm - I like to give things a go - but generally it's 1st time for everything and you don't find out what you've done wrong till you do it...like with the other thread above..the manuals don't tell you whats gone before - ie in the transmission section it doesn't mention anything about aligning the dots on the primary & idle drives (timing) when fitting the clutch cage. However, this is covered earlier in the re-fitting of the primary & idle drive sections (which I wasn't doing so didn't look at!!).
Why don't you think changing the engine is the way to go?? A full rebuild will cost more than the bike is worth if I get someone to do it. If I do it it may never run again...lol

zaga · Apr 20, 2014

My first question, and that is the question, how much does your old companion worth to you ???

Cheers
ZAGA

Big Berg · Apr 20, 2014

Sorry to hear of your troubles!

I would want to know WHY my cam went flat........I suspect poor maintenance of air filter and oil/oil filter.

Once the Stellite coating is worn from cam lobe it is a quick descent to a flat lobe.

arkley123 · Apr 20, 2014

Hi Zaga - not what it's worth but how much do I have.
I'm very attached top my berg and may even undertake a complete re-build including frame re powder coat etc but that may take some time & what to do in the meantime.

Big Berg - as my boy does mx - I'm pretty hot with oil filters / changes & air box cleaning etc so none the wiser as to why. (Perhaps not so good with the valve adjustments & bearing checks??). Interesting though re the stellite coating.

tourist · Apr 20, 2014

makazica had a similar situation w/ a disappearing cam - "When I took the valve cover off there was a surprise waiting, never seen something like it. Mint from outside, a graveyard from inside..... I'm surprised it even started..... "

made for a really good thread!: http://husaberg.org/mechanical/16777-fe-450-2005-force-edition.html

makazica · Apr 21, 2014

As tourist said I have very fresh memories.....

For me it was a dilemma to strip and rebuild or to strip and only clean. When I opened it up it was clear that it needed a rebuild because metal shavings caused other parts to wear.

In your case I would strip the engine and than make a decision which way to go. If you appreciate the old Husaberg you own and want to keep it.....

Cheers!

M.

arkley123 · Apr 21, 2014

Ummm..will probably do that...but as a project for me...fun but will take a long time or pay someone??

But as you say, I can't believe that the fine tolerances that these temperamental birds work on, that it even ran, and in fact was running really nicely??

zaga · Apr 21, 2014

arkley123 said:
Hi Zaga - not what it's worth but how much do I have.
I'm very attached top my berg and may even undertake a complete re-build including frame re powder coat etc but that may take some time & what to do in the meantime.

Hi, I know what you mean, I have the same problem !

I use to say that with a berg you have 2 hobby's, one is riding it and the other is repairing it ... not necessarily in this order

My only concern is that a complete rebuild for a first job, just might be a little too much, but if you take your time it might just work. I'm sure you will have all the support from the brothers of this forum

You won't know what you need until you have opened it.

Cheers
ZAGA

makazica · Apr 21, 2014

arkley123 said:
Ummm..will probably do that...but as a project for me...fun but will take a long time or pay someone??

But as you say, I can't believe that the fine tolerances that these temperamental birds work on, that it even ran, and in fact was running really nicely??

As Husaberg is discontinued, at least in Croatia parts prices went up for cca 15-20% so above all it is a expensive job. It took ma almost 8 months to fix it, gathering money, finding cheaper parts, etc. I did all the work myself and I'm not a mechanic, I do this stuff as a hobby.

When I got all the parts and prepared all I took everything to a mechanic - friend's place and assembled it there. When I wasn't sure about something I asked him to help.

Bits and parts cost me more than 1000€.....

M.

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