Fe450 Con Rod kit

husamert · Jan 28, 2014

hi,

does any one know the dimensions of 04-08 husaberg fe 450 conrod (81030015100)?

i need a conrod (81030015100) for my 2005 (04-08) husaberg fe 450. The oem part is too expensive. so i want to buy from pro-x, wiseco, carillo, etc. There is no match for it in prox stocks. in some forums people say that they found a prox conrod for ktm which is the same as my bike but 1mm. shorter. 1mm. is too much. may be i can fix this by a 1mm. longer bore size piston. but it is risky.

ANY SUGGESTIONS ABOUT ?T ??

i mailed prox and they replied no match in the stocks and asked for the dimensions to help. if i can learn the dimensions of my conrod maybe pro-x or carillo or etc. can make it on special order.

thanks...

bushmechanic · Jan 28, 2014

if i had one id measure it up, i have 550 and a 628 rods

the length is in this table in the DOC but im not 100% sure its right, the length for the 628 was slightly wrong till we fixed it up a couple of years ago

http://husaberg.org/wiki/index.php?title=Engine_tuning

the big end pin diameter is defiantly 32mm and little end is 20mm, assuming the ends of the rod are the same as the 550 ... the big end and the little end of the rod are 19.9mm wide

MMX composites would have the dimensions on file .. so may Carrillo, can't hurt to ask.

hacker33 · Mar 15, 2014

Today I opened my engine - FE 450 E '04.
I look and there's con rod Prox 03.6423 and Wossner piston 8593D.
I bought motorcycle with this set. I drove him 10mth.
Everything worked great.
Strangely I did not notice that the piston was below the cylinder surface. A should be about 1mm?
I am writing this just for information.

2014%5C01%5C19%5Cbikepics-2634163-800.jpg

2014%5C03%5C15%5Cbikepics-2651128-800.jpg

2014%5C03%5C15%5Cbikepics-2651130-800.jpg

bushmechanic · Mar 15, 2014

Nice pictures, thanks for those

yes this rod is the prox ktm 450rfs rod and is 119mm in length center to center, the oem rod is 120mm

the piston 8593 is listed as being the STD husaberg 450 piston for 04-08 and has a deck height of 24.3mm

so yes 1mm below the top of the cases sounds spot on

if you could find a piston (or have one made by CP) with a 25.3mm deck height you could get your compression and squish back to standard. there is a wossner one i'll check my notes later

does this pro-x rod have a bronze bushing inside at the small end or is it steel ?

cheers
Bushie

hacker33 · Mar 16, 2014

does this pro-x rod have a bronze bushing inside at the small end or is it steel ?

It's steel. It may be a problem with that?
OEM has bronze, right?

there is a wossner one i'll check my notes later

this one
http://www.wossnerpistons.com/produ...ame/wossner-piston-gasgas-sm515-99-99-mm-bore

99,95mm
25,50 comp.height
the same pin, only the rings are different
no pics :?

bushmechanic · Mar 16, 2014

yes that's it

2009 GasGas SM 515

weight 300gm piston volume = 0 so i reckon its just the std 550 piston with the pin bore lower down

Part Number 8703DA
Bore Size 99.99 mm
Clearance 0.04 mm
Compression Height 25.5 mm
Compression Ratio
Cylinder No. 1 Cyl./Kit
Displacement 515 cc
Dome Volume
Engine Code
Piston Weight 299 g
Stroke
Valves/Cylinder 4
Gasket P/N
Lock P/N CW20
Pin P/N WP038
Ring Set P/N 1000ADS
Rod P/N

most of the jap 450s use steel little ends they seem ok but yes i reckon bronze is better

the wiseco rods have bronze inserts ..

hacker33 · Mar 17, 2014

Nowhere images with this piston.
I'm afraid that its upper surface may be different than in the Husaberg.
Valves pockets will be different and valves meet with the piston at the first crank turn.
If someone has tested it then ok
If not, I will not risk £110

bushmechanic · Mar 17, 2014

if the pockets are close already the cutter made from the valve doesn't need to be so complicated.. just a spot of weld on the OD and then sharpen it up

Pretty sure the gas gas has bigger valves and more valve lift than our bikes so should be fine.

hacker33 · Mar 17, 2014

My fiend sent me pic of oem piston from 515.

2014%5C03%5C18%5Cbikepics-2652006-full.jpg

2014%5C03%5C18%5Cbikepics-2652005-full.jpg

This cutter made from the valve looks crazy.
That's your idea? You tested it?
How it's look the piston after that?

bushmechanic · Mar 18, 2014

that idea was actually shown to me by contiman

its no different in principle to setting the piston on an angle in a mill and using a facing cutter to deepen the pocket

I have done it with only one cutting surface like a fly cutter. the result is the same as in the mill.

this one is done with a valve as the tool and gives you the same result as doing it in the engine

[youtube:37xo1wre]http://www.youtube.com/watch?v=c4W2p_8aXxI[/youtube:37xo1wre]

this one is done with a rottler cnc machine

[youtube:37xo1wre]http://www.youtube.com/watch?v=zYQ-kUhinmY[/youtube:37xo1wre]

http://www.youtube.com/results?search_q ... iston&sm=3

looking at those pockets though I think they are very close to what you need maybe even bigger.

bushmechanic · Mar 19, 2014

some more pics

the sandpaper glued to the valve is a nice one

I made on like this

commercially available for use with a drill and mounted in the valve guide

or use a lathe

bushmechanic · Mar 28, 2014

looks like 1 prox failed

spudo said:
Looking for feed back on pro-x conrod kit. put one in my 05 450 only lasted 3000km hard facing came of pin it looks soft also notice that oil hole is 180 deg out compered to OME pin. Hav installed another pro-x kit will see how long this one lasts.

viewtopic.php?f=5&t=18380&p=148903#p148903

bushmechanic said:
hotrods ktm 450 rod $135

http://www.mxmegastore.com/HOT-ROD-KIT- ... 1-8665.htm

not 100% sure of the detailed dimensions .. will have a look later

bushmechanic · Mar 29, 2014

WArdogG said:
Not many details, but basic details from the HotRODS catalogue

Center to center 119.1mm
small end 20mm
big end 41
s/e width 19.9
b/e width 19.9
pin dia 32
pin lenght 64.7
s/e bearing : brass bush
b/e bearing 32x41x19.8

seems they are using some other big end bearing which is 1mm smaller @ 41mm, instead of the standard 42mm
I may get one later this week, if i do, will post some pics, measure the b/e rollers, and count the number of rollers, etc.

WArdogG · Apr 9, 2014

Hey guys.
I have that HotRod conrod I want to try in a 450 build.
18 rollers in bigend pin
rollers are 15.75mm wide
and 4.5mm diameter.

I can check the oem bigend bearing, and also the pro-x b/e bearing for comparison, if anyone is interested.

Then there's the question of the oem conrods (2 from 450's and 1 from 470)I have which also measure 119 c-to-c, and not 120 as it's supposedly supposed to be...

Except of course if they were changed to the oem ktm conrod on previous rebuilds, which I wouldn't know, since both bikes were bought second hand.

WArdogG · Apr 9, 2014

Can we somehow join these two topics, as they are both regarding the same thing...
http://husaberg.org/mechanical/17426-pro-x-rod-kit-fe450-2.html

bushmechanic · Apr 9, 2014

thanks wardog it would be interesting

do you know what were the squish and piston deck heights on the "oem" engines with the 119mm rods ?

hacker33 · Apr 9, 2014

WArdogG said:
I can check the oem bigend bearing, and also the pro-x b/e bearing for comparison, if anyone is interested.

It would be great.

Anybody know what differences are between 2004 and 2005 conrods?
810.30.015.000 CONROD REP.KIT 450 03
810.30.015.100 CONROD REP. KIT 450 05

bushmechanic · Apr 9, 2014

probably 1mm

WArdogG · Apr 9, 2014

Unfortunately I never bothered to take any measurements when I disassembled, but I still have the 450 cranks in one piece, so I will slap them in the cases and check. The 470 crank has already been pressed apart.

I will post those up later.

I have a question regarding the inner race of main bearing spinning on the crank, but I will post on the 'Definitive Main bearing thread'.

hacker33 · Apr 9, 2014

bushmechanic said:
probably 1mm

I hope that 2005 model is 1mm longer

Then 2004 model will have a 119mm and I am at home.

Fe450 Con Rod kit

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