crankcase heights

the 04 is in fact a 649cc 100 x82 stroke.

I have a new OEM 2003-2004 rod in my garage that I measured up,look well it is still in coverplastic.

small end dia 20mm
there are 2numbers on the rod 140 and the otherRO4
the big end 32mm
from middle small end to middle big end indeed 135mm

Hopefully this in helpfull to somebody

eeeeh?

Madero

that isn't right? the big end is 40mm so simply measure the nearest point of the two holes and then add 10mm plus 20mm.

regards

Taffy

madero said:

the 04 is in fact a 649cc 100 x82 stroke.

I have a new OEM 2003-2004 rod in my garage that I measured up,look well it is still in coverplastic.

small end dia 20mm
there are 2numbers on the rod 140 and the otherRO4
the big end 32mm
from middle small end to middle big end indeed 135mm

Hopefully this in helpfull to somebody

Click to expand...

Thankyou faktor/madero.

I was of the mistaken belief that the 628 arrived in 04 along with the Kokusan- seems I was wrong as usual :lol:

But on the positive note, whosaberg and madero both concur on a 135mm rod with 32mm big end for the 04 650.

faktor has measured his 05 628 rod up for us- it is a 35mm big end and approx 136.5mm- but as he didnt have a vernier handy that length is only approximate- not definite.

cheers ausberg

it is relatively easy to measure from the edge of each hole in the rod and 136.5 would make sense! if i remember correctly someone discusssed the 550 rod as being 135.5 at some time or other!

i think we've answered most things on the 650s now. we just need to know about simon's 140mm rod and a whole bunch about the actual cases themselves. we know very little about the 501/550 cases but in one of the three links i left yesterday, dale does explain which head goes with which case.

i trust the 450 cases are lower but we'll have to catch someone splitting an engine for that!

regards

Taffy

Taffy said:

we just need to know about simon's 140mm rod

Click to expand...

As I said, it was boxed and labelled up as an 03 650 conrod. I believe it was mislabelled but we may never know. My own 03 conrod I will measure up when it is time to split the cases.

All the best,
Simon

Simon said:

The 2003 650 conrod is 140mm pin centre to pin centre. It even has 140 stamped on the side, which I assume designates its length :wink:
On my 2001 650 the piston was at TDC 3.2mm below deck height.
At least you have your 140mm conrod now Taffy!
Simon

Click to expand...

so we have a rod that's yours a rod that's in a box and an '01 that's yours but you can't get at it? you lead an interesting life si!!!!!!

i think you need to give GG a call.

regartds

Taffy

Taffy said:

so we have a rod that's yours a rod that's in a box and an '01 that's yours but you can't get at it? you lead an interesting life si!!!!!!

Click to expand...

You haven't been reading my threads have you Taffy?

RTFT! :wink:

Simon said:

No, I told you I wasn't going to touch my 03 :wink: Lets get this clear - just for you I pulled some strings and I measured a brand new KTM boxed conrod marked for model year 03 which came to 140mm. Measurements are 110+10 (l/e diameter/2)+20 (big end diam/2)=140mm

Click to expand...

As I said, I have measured up the 01, not measured up my 03 but measured a 650 03 conrod in a KTM original parts box.

Also further up this thread you'll see my deductions about the 140mm conrod v. crankcase and cylinder head - it just wouldn't work on the 650 but would with the same crank case height and shorter stroke.

All the best,
Simon

i've read the phuqing thread simon....

i don't follow your last paragraph.

regards

Taffy

Hallo! I have some spare time now, vacation and ist just raining so i did some research in the different years sparepart catalog and come out with this. 07 catalog its not out on Husaberg.com but I think its the same as 06 in the engine. now I`m talking about 650

Small/valve cylinderhead 35-30 came 04 and are the same to 06
prtnr 800.36.020.044

Conrod kit aka Conecting rod kit
01-02 the same. Part nr 210192-01
03 Part nr 210 192-02
04 Part nr 820.30.015.000 probably the same as 03 just new partnr system
05-06 Part nr 820.30.015.100
07 Probably the same as 06 but not out on manual.

Crankshaft

01-02 82mm stroke Part nr 210163-01
03 82mm stroke Part nr 210233-01 nr in 03 manual
04 82mm stroke Part nr820.30.018.000 in 04 manual the is says 03 the shifting year. so i think this also is the same but new part system.
05-> 80mm stroke Part nr820.30.015.100 New lightened and strengthened

Piston

01-02 partnr 200 246-01 01-03 in 03 part catalog but in 04 catalog it say shifting year 03-04
04 Partnr 820.30.007.000 probably 03 also. In my 650 04 its zero deckheight.
05 Partnr 820.30.007.000 the same as 03-04
06 Partnr 820.30.007.100 probably elko light piston zero deck height.
07 dont have part nr but probobly the same as 06

Cam
01-02 Partnr 200230-53 Fs400c/470/550/650 01-02
03 Partnr 200342-08 Probably the same as 04 but old nr.
04 Partnr 820.36.010.000
05 ------------||--------------
06 ------------||--------------

Best regards Patrik

swedishsteel said:

talking about 650

Small/valve cylinderhead 35-30 came 04 and are the same to 06
prtnr 800.36.020.044

Conrod kit aka Conecting rod kit
01-02 the same. Part nr 210192-01 - 134 long
03 Part nr 210 192-02 - beefed up
04 Part nr 820.30.015.000 new part number and steel caged big end bearing
05-06 Part nr 820.30.015.100
07 Probably the same as 06 but not out on manual.

Crankshaft

01-02 82mm stroke Part nr 210163-01
03 82mm stroke Part nr 210233-01 nr in 03 manual
04 82mm stroke Part nr820.30.018.000 in 04 manual the is says 03 the shifting year. so i think this also is the same but new part system.
05-> 80mm stroke Part nr820.30.015.100 New lightened and strengthened -pork chop crank, 35mm big end necessatating a different rod

Piston

01-02 partnr 200 246-01 01-03 in 03 part catalog but in 04 catalog it say shifting year 03-04
04 Partnr 820.30.007.000 probably 03 also. In my 650 04 its zero deckheight.
05 Partnr 820.30.007.000 the same as 03-04
06 Partnr 820.30.007.100 probably elko light piston zero deck height.
07 dont have part nr but probobly the same as 06

Cam
01-02 Partnr 200230-53 Fs400c/470/550/650 01-02
03 Partnr 200342-08 Probably the same as 04 but old nr.
04 Partnr 820.36.010.000
05 ------------||--------------
06 ------------||--------------

Best regards Patrik

Click to expand...

that's about it?

taffy

well i believe i have a final crude figure for the crankcase heights.

the measurent i took was from on top of the casting on the RHS case that is drilled for the top screw through the ignition cover. having a 400 and a 650 here i asked ady to measure a 501 case for me.

the measurement was to the top of the cylinder head gasket 20 1.5mm has been removed from these figures:
400/470 case; 95.5mm
501/550 case; 106.5mm
650 case; 123.5mm

11 plus 17.

this was my guestimate!

"Crankcase heights
We can't confirm exactly but the 501/550 cases are thought to be 9mm taller than the 400/450/470 cases. The 630/650 cases are 29mm taller than the 400 cases"

so if you were thinking that that 650 felt 'top heavy'.....you were right!

regards

Taffy

I have just measured my 05 650 deck height admittedly only with steel rulers and I get 200.5mm from crank c/l
to top surface where the head gasket sits.

This is the same measurement that AUSBERG got.

The bottom end is still assembled and I am trying to determine the compression height of the 05 piston;

200.5 - 40 ( stroke/2 ) - 135 ( rod c to c ) = 25.5 + .25 ( piston above deck )= 25.75 compression height

If anyone has a 650 piston from 05 onwards that they can measure to confirm my measurement/calculations please feel free to check.

Compression height is from the top of the piston to the centre of the piston pin.

Or from the top of the piston to the top of the piston pin hole + 10mm.

Cheers spanner

the 100mm Elko from my 08 measures 24.5mm

Thanks Bushie,

I will have to have another look at it :?

OME 05 rod 136mm between centres I have been told.

That brings me a lot closer.

Bushie do you recall if your piston was flush or up .25mm like mine?

Cheers spanner

pretty sure it was flush, won't be anymore have decked the block a bit

08 rod I have here measures 136.17mm between centres say its sposed to be 136.2

Thanks Bushie, 136.2 ( not a very log rod :twisted: ) would bring me within .05mm.