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Engine Blows-up

acyr

acyr

Joined Sep 2004
32 Posts | 0+
Well, after only 49.9 hours on the engine of my 2004 FS650, blew-up this morning.


Not sure what happened, I was only at about 1/3 gas doing a sighting lap, and then the engine staled and heard what sounded like a chain going off a sprocket or something similar. I pulled into the pit and then see a major oil leak.....just to find a hold the size of a golf ball on the left side of the engine. The hole is just in front of the oil window and also extends to the main engine case.

So looks to me like I'm screwed. Not sure what to do. How much is an engine replacement?
 
get the sidecover off mate, take some photos and get them up here. we can help with anything and yes we'll even guess for tabs but why not take the photos or get it all undone and describe it.

needn't be the end of the world. just seems like it!

regards

Taffy
 
Engine replacement, you do not need one, I don't think so, but first you need to open the side cover and tell us what you see.

Something caused the blow up and after 50 hours, it seems a bit strange that it happens.
 
Taffy, I will upload pictures when I get a chance.

Husasaint, I had the bike for over 1 year, plus missed out on the 1 year warranty anyway since mine did not come with one.

After briefly talking with Dan at Motoxotica, he's thinking around 3k to repair, of course we won't know for sure until I open the thing-up. I will post pictures.

Thanks
 
Before looking around for service quotes I would first remove the left cover and look. Where is the hole? Can you take a photo and post it?
 
can't post any pictures for some reason. The picture is only 300k so it should not be an issue?
 
i'll PM you now with my email address. please send the photos to me.

regards

Taffy
 
I've sent some pictures to Taffy since I can't post any pictures. It looks like it's the primary gear that broke in half, spitting my case open. Also the nut that's holding it in place was realy realy loose, not sure if it loosened-up after the gear broke, or if the gear broke because it was loose.
 
ok, you had a clean snap of the gear. the good news is that the crank is ok (bar a clean up) and so is everything else in the side cover. unfortunately, the only photo you didn't do was a photo of the gear without
the nut on it. i need to see if there was any chaffing. another good photo
would be the gear from the side where it has broken, this will tell us if it was gear failure.

undo the rocker inspection caps. turn the gear with the camchain behind it
till all the valves are closed. you'll need a long 30mm spanner and to
control the camshaft. go anti-clockwise till the inlets have opened and
then closed. you should feel the nut is free and easy in the middle of
opening either set of valves if moved too far in either direction. stop the gear in the middle.

adjust your tappets. if you have no problems with the tappets - you have
not bent them!

so you only have to pay for new cases and and a new gear as well as a gasket
and some oil etc etc. the labour is the biggest cost.

i'd upload them to my gallery page but the site won't allow it today?

i'm afraid folks that this has to go in the red alert in the doc coz it has happened too often now....

regards

Taffy
 
So looks like I would need to replace a left side case, primary gear, possibly the outer clutch hub, gaskets, not sure if the vavles were damaged.

Anyone dare to put a price tag on this with labor if I am not doing the work myself?
 
The checking and retorque of the primary drive nut is something that is part of regular maintenance at my shop.Esp on the 550 and 650 engine.
It is usually very apparent as a loud clicking noise as the nut backs off.
This is also an issue with the YZ450 engine.
We have never witnessed a gear that has shatterd,always was caught before.
My theory is that the torgue reation on the nut on quick crank deceleration is the root cause for this,and is most often seen on motard and road racing bikes.
 
acyr

do the valves first. do your bit mate. i know you're keen but let's get that done.

regards

Taffy
 
well wish I would have know of this maintenance item before. Unfortunetly I did not ear any clicking noise until it was to late, it did hapen when i was off the gas, but no warnings for me.
 
Some of the primary drive nuts on the 05 models were torqued incorrectly at the factory. Perhaps someone can forward Taffy a copy of the bulletin as it lists which Vin numbered bikes were affected and he can add the information to the doc.

As nsman states its probably a good idea for everyone to check theirs periodically.
 
but it seems to be the '04s that got it eric?

look forward to a copy of the bulletin. go to joe's gallery and you'll see he's been collecting them over the years. does he have a direct to mr larsson!

regards

Taffy
 
ok so followed Taffy's direction on checking the vavles and it seems like there is a problem there also. Anyone know were I can get used parts? Thiking especially for the engine's left side case, since I think this is realy expensive. If i can't find used parts I will probably put in the classified section. Anyone need spare parts?

Running a Husaberg is not cheap, if I have to punt this thing it will have cost well over $200 per hour to operate, that's not counting gas, oil or tires.
 
HMS does not have any used left side case. any other suggestions anyone? Would be nice if Husaberg could step-up and help in situations like this, especially when it's a documented issue. A bulletin sent to owners advising them of this issue would have been nice.

Anyone ever converted their Berg into a bicycle?
 

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