cappucino! water in coolant

Taffy · Jul 12, 2005

oh dear!

found some bubbles in the radiator when i started it at the weekend so i set out to re-torque the head and alas my engine is creating cappucino coffee!

i have just rebuilt the engine after it's first tear-down.

so to cut to the chase and i'll give you all the warts on what it could be and you tell me what to look for?

skimmed the block and spigot seperately and then put it together by lightly tightening the cases, then torquing down the head and then torquing the case bolts. one of the three 'o' rings broke in my hand upon doing the rebuild. no black lines tonight from water leaking.

fitted another cylinder head which i cleaned up with a block and some wet 'n dry. new head gasket which torqued past the 45Nm straight to 60Nm.

counter shaft had laquered feature on end which i had to scrape to break, cleaned up with scotchbrite. new oil seal, new bearing at both ends, new gasket. also new 'o' ring to sidecover. didn't replace 'o' ring on the actual shaft.

ideas please!

regards

Taffy

JoeUSA · Jul 12, 2005

Hi Taffy,

How about that side cover gasket, did you relieve it for the O-ring? (water in the oil)

If you are seeing bubbles in the water and water in the oil, then its got to be a head gasket leak or worse, a defect in the head or the top of the sleeve. One that allows combustion gases to get onto the water and water into the oil.

Which head did you use, the one that was on the bike when it ran out of water? Maybe it is cracked!

Did you have the proper head gasket? There are at least 3 different patterns for the 02 Husaberg, plus different thicknesses in each pattern.

Or it could be caused through your assembly techniques, there I said it!

If you went directly to a high torque level on the head fasteners without installing each finger tight, and then torquing in a cross pattern in small increments, it might be at the head gasket.

Regards,

Joe

Taffy · Jul 12, 2005

JoeUSA said:
Hi Taffy,

How about that side cover gasket, did you relieve it for the O-ring? (water in the oil) joe. they now come with the gasket relieved in that area already

If you are seeing bubbles in the water and water in the oil, then its got to be a head gasket leak or worse, a defect in the head or the top of the sleeve. One that allows combustion gases to get onto the water and water into the oil.yes i agree this is the area to look

Which head did you use, the one that was on the bike when it ran out of water? Maybe it is cracked!i used a head that has never been on before-it's the same type and it was all cleaned up and prepared but it wasn't skimmed

Did you have the proper head gasket? There are at least 3 different patterns for the 02 Husaberg, plus different thicknesses in each pattern.now i've been told that there was only ever one thickness of headgasket but i know that you-like me but you're better at it-like to read up what's in the later parts books. this is COMPLETELY new to me, are you sure this is right?

Or it could be caused through your assembly techniques, there I said it!of course! put together on a budget and in a rush by a virgin!

If you went directly to a high torque level on the head fasteners without installing each finger tight, and then torquing in a cross pattern in small increments, it might be at the head gasket.as i have said that 'black stain' isn't there and i did do it in a 'x' pattern

Regards,

Joe

cheers joe
i didn't know about the three thickness' of headgasket! i have asked in a previous life but didn't know this...

i had the spigot and block machined and had a spigot 'o' ring break. i'm trusting that 2 would do the job.

if dale reads this;
can a machine shop tool maker do a neat job of maching the head by going around the combustion chamber to skim it? PS do you remember putting up a photo of a head being turned in a lathe?

thing is; with inlet seats sitting loud and proud i can't really have the head skimmed!

off to check the parts manual! thanks joe!

regards

Taffy

dsducati · Jul 12, 2005

A well tooled machinest with a tight and true bridgeport could do what you are asking.
dan

JoeUSA · Jul 13, 2005

Hi Taffy,

Yes here are the numbers and descriptions, item 21 right out of the 2002 Parts Manual.

21 200 319-01 Cylinderhead gasket 400 (thick) -01
21 200 231-01 Cylinderhead gasket 400 -02
21 200 320-01 Cylinderhead gasket 501 (thick) -01
21 200 232-01 Cylinderhead gasket 501 -02
21 200 321-01 Cylinderhead gasket 470/550/650 (thick) -01
21 200 233-01 Cylinderhead gasket 470/550/650 -02

Remember, in 2002, Husaberg had 3 engine bores; 92mm, 95mm, and 100mm. The Head gaskets are not interchangable between bore sizes but of course the thick ones can be used if you want to lower the compression ratio.

Regards,

Joe

Taffy · Jul 13, 2005

joeusa

so we all get the standard one and the thick one is the one you order... i trust so anyway.

regards

taffy

Simon · Jul 14, 2005

Taffy,

As you suspect already, I'm afraid you may have to re-do your engine assembly.

As part of the assembly the crank case halves really do need to be tightened to torque prior to the instalation and tightening down of the cylinder head.

I wonder whether your procedure of doing it the other way round may have prevented the 2 case halves from sealing properly around the cylinder liner. It may also have caused a final liner position that isn't quite true, which may also cause you serious problems.

In addition, 60NM for the cylinder head is too much. On 01 and 02 bikes it was 44NM and this went up to 55NM in 2003.

Being pedantic, the tightening procedure should be tighten the cylinder stud nuts crossways to slight resistance, then to 40nm and then to the required final torque.

Cheers,
Simon

Taffy · Jul 14, 2005

cheers simon!

i'm 90% certain that it's going to be the three massive 'O' rings. one fell apart in my hands at rebuild time. GGs advice on what needed renewing still holds good it's just not every day that a bike runs for 2.5 hours with littl or no coolant (we shall never know...). the three 'O' rings are just below the waterpump exit/entry and there was a dark soot mark opposite the here on the spigot. it took 5-minutes to scotchbrite it off.

the 'O' rings would have been sat just 1" away. hot or wot!

i lightly tightened the case halves to allow only movement under intense loading from the head. there has been no leakage from the head. it was only the 4 bolts near the top of the block that i didn't torque initially, the rest were done and the 'O' rings are quite low.

i was advised by mick at SR off-road about the torque settings and the difference of 5nm is minute. cross torqueing is a given. 2-stage is more than enough on a single.

at the end of the day, even though i had preprepared many parts for the rebuild i was in a hurry and only had it running at 7pm on the saturday evening.

sometimes you have to back yourself to get these things done. the race team that says it never has these problems either doesn't race or is lying!!!

regards

Taffy

cappucino! water in coolant

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