Engine Rebuild

BelgiqueBasterd · Nov 8, 2006

As you might have read in my other thread, I've been having some problems with my 2002 husa 650, I was planning on an engine rebuild this winter anyway, so I'm gonna move that up a bit and start on it now.
When I go and order all my parts from the dealer I want to have as much info on the parts i need to prevent any mistakes on my or his part. So if the people who have done these upgrades and have some time on their hands, please help me out here. Part numbers would be perfect offcourse!

Plans are:

- New valves and valve springs, any aftermarket ones that are better than the stock ones? Or should i just get Husa stock valves? Any differences between different model years valves and if so wich are the best ones?

- Upgrading the rocker assemblly, if I'm not mistaken the rocker assembly changed on the 2004 model? So do i order the 2004 assembly or are the later model years rocker assembly even more reliably? Is the rocker assembly sold as a kit or every piece seperatly?

- Upgrading the main bearings from ball bearings to roller bearings.. Wich model year bearings do i have to order? (are the bearings custom made for Husa or can they be ordered directly from a local SKF or other brand bearing dealer? Would probably be a lot cheaper than going through Husa.)

- Upgrading the cam sprocket, from aluminium to steel, again wich model year sprocket do I order?

- Upgrading the tensioner blade and tensioner, how does this work wich parts will I need for this?

- Upgrading the timing chain, and once again wich model year do i want?

-Upgrading the cam, i have read on this site that the lineaweaver cam is the way to go with these bikes, so where can i get one and even more important wich type of cam do i need, I tried to read up a bit on this site about cams, but don't understand a thing of what is being said

. Bike is street supermoto, no racing (apart from an occasional track day).

- Decompression thingie, just order a 2002 one or do the newer models have upgraded decomp things?

- Also read somewhere on this site to upgrade the balancer bearings, is this necessary for a non tuned machine? If so, wich years bearing do I need to order.

-Any other upgrades you guys recommend while I'm rebuilding it anyway?

Thanks for you time, if anyone could point me into the direction of a site where stuff can be ordered I would be very gratefull!

kez · Nov 8, 2006

Right,Cam Wise I Think The X2 Is Regarded As VERY Good,Could Be Wrong And Its The X1,Both Are Dales Cams.
The Newer Bikes Run An OEM Cam Thats Very Close The His Specs,So What Does That Say.
If Moneys No Object....
1) Lineaweavers Cam Or New Cam,Think Its 008?
2) '03 Rocker Arms
3) '03 Tensioner Blade And Tensioner If Yours Is Tired.
4) Balanced '05 Crank Assy Complete With Bearing Mod,Reduces The Risk Of Snapping The Crank Pin And You Can Do Away With The Balancer,As For Bearing,Have No Idea There Is So Much Choice.
5) Dale Does Some Over Sized Valves If Your After Some Extra Power,But These Will Require Some Modding To The Head To Get The Best Results From Them,Otherwise Standard Valves And New Springs.
6) Either Dales Cam Chain He Supplies Or The New DID One,My Rebuilt 450 Has The DID And My Dads 400 Has One Of Dales,Both Bikes Have Less Than 2 Hours With These Chains,So I'll Let Everyone Know How They Compare.
7) I'd Upgrade To An FCR At This Stage As Its Common Knowlege That They Make The Bike Sooo Much Nicer,Either Use Dale Jetting Kit Or Taffys Recommended Jetting....Or A Combo Of Both.
8] After Doing The FCR I'd Get A Full Exhaust System Or Better Silencer,Ebay UK Has Had Some Nice Akra Silencers Lately.
9) While The Motors Being Rebuilt And Having The Updates Might as Well Send The Stator Off To Sparks To Be Rewound As It Seems To Be A Little Suspect.
10) Forgot To Add About The Cam Wheel,Think From '03 They Were Steel,Think '04 The Decomp Was Revised,The Cam Wheel Fits Straight On While The Decomp Takes A Little Modding To Fit,Think The Bolts Need Shortening Or Something.

If Your Doing All This Work And Your Like Me I'd Grap A Spray Gun And Paint The Frame,Engine And What Every Else Is Painted,Send The Wheels Away To Be Powder Coated/Anodised And A New Seat Cover/Decals And Plastics.

Sorry Got Carried Away There

Others Will Help You Out If I've Gone Over Board Here.

Here Dales Webpage http://www.d-lineaweaver.com/

Taffy · Nov 8, 2006

the rockers from your '02 should already be modified and therefore they're ok as they are. the doc has photos of what the upgrade should look like from the side. essentially: standard looks like a pin, modified looks like a dowel within a hollow pin.

the later the cam the better the decomp became. the factory cams are now a match for dale's cams so again, one of those will do. get the decomp with it and the later steel camwheel. the alloy camwheel was wider than the steel so the bolts will protrude through too far. cut a little off.

i wouldn't change the crank until i was sure that the later crank end that takes the kokusan is the same as the early crank. otherwise the ignition won't fit!

valves, standard valves and springs appear to have stood the test of time. not heard of a softer spring to match the newer profile. has anyone?

as for upgrading to rollers, well it appears the crank needs to be axially perfect across the two crankcase halves. unless you're prepared to have an engineer test and machine them. leave them alone. within 1" will do ball-race but .002" out will knacker the rollers.

all bearings are proprietary parts so just get all the codes off the doc and get them yourself. yes you should upgrade to double row roller bearings in the balancer. do a search for an old thread on this. my 400 doesn't need them so i've never got involved.

don't forget YOUR hours on the bike? you don't need new cam follower upgrades if done already BUT, BUT, BUT the hours might be up. 50 hours for MX and 100 hours for enduro. these can be exceeded (at your peril) by up to 50% but you take that chance....

download the parts books and at the end of each part no. it says the year introduced....

go through the engine rebuild and the tuning part of the doc for ideas and clues on stuff.

good luck and do let us know.

regards

Taffy

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