Help !!!!!!!!!!!!!!!!

while riding at the end of this past year a terrible banging noise started coming from the motor, stopped and and turned the bike off, waited until no other bikes were around and started it back up and the same sound was still there. didn't leave it running long enough to pin point the location other that the left side of the motor.the banging was that loud. previous year i had 3 of the dowl pins come out of the shift drum behind the star gear, chewed at least one dowl into metal dust and mangled the rest, felt fortunate i didn't break the cam chain or sprockets. Only damage was to the outer gear of the clutch basket, chipped one of the teeth but not enough to warrant replacing. I thought i got all the pieces, even removed the rocker cover and found a few pieces laying in the sump. long story short i should have taken the motor out and split the case and searched further. but being early in the summer didn't want to miss any riding, so i took my chances. Well yesterday i tore her down and here's what i found. wasn't a dowl at all. the lobe on my auto decompress that swings out had broken off. mangled one of the hex head bolt that holds the upper cam chain sprocket and the head right next to the front cam chain guide. the piece that broke slid between the front cam chain guide and the head, pushing the guide tight against the cam chain. not sure what position the adjuster was in as I took it off before i found the broken piece. i checked it earlier in the year and had 5 notches left. the chain was bowstring tight. i have a trail tech endurance with water temp, bike usually runs right around 250 degrees F in tight single track and climbing hills. didn't really worry too much as i read where temps can run up to 270 degrees and i use a 50/50 mix of dextron(for aluminum radiators) and water. must have gotten hot at some point as piston skirt and cylinder walls are scratched up now. I think i can crosshatch the skirt of the piston and reuse it but cylinder definitely needs relined. So as of right now I need of course a new auto decompress assembly $90 decompress spring $12 and gasket kit and front chain guide $12 and gasket kit $45. First question is when I was checking the connecting rod there is a tiny bit of play, very little when the con rod is in the lower position, but very tight when its in the upper position on the crank. Is the play coming from the con rod resting being between 2 rollers of the bearing in the lower position and resting squarely on top of a roller in the upper position? The bike is a 99 fe400e and not worth dumping a whole bunch of money into at this point, but I hate like hell to part it out. Wanted to get a Triumph speed triple this spring, so cost vs "is it worth it" is coming into play. If i fix the bike I want to do it right. Checked on a new piston and its $450 from husaberg not counting the rings, they are another $100 for both the oil and compression ring.cannot find an after market piston at all. Anyone know of one? a new con rod kit is $291 which if i need one i'll get it. remember the bike at best might be worth 2 grand, but I hate to dump a bunch of money into it at this time. I don't trust ebay for internal engine parts, so thats out, so if anyone has any idea about a piston and con rod I'm all ears, i want to do it right while i have it apart, but don't want to spend too much money that i could be saving for a newer one. so anyone that might have info on any quality after market parts I'd would greatly appreciate your imput. I split the case tonight and lower end looks fine with out any damage other than i did find a piece of dowl and lightly scratched the harmonic balancer...but no pieces got into any of the teeth of any of the gears......whew.

well your judgement so far has been floored so why i are you knocking ebay only to say one sentance later "does anyone know any aftermarket...". as you know now, you should have stripped the motor.

the '99 was less work than lego but it's too late now.

you've supplies prices from your end in $, so i'll give you them at this end
decomp and spring are just £25
a piston is £135 complete
your big end pin is worn away. when the pin is at 6 o' clock, the pin is worn on top and the rod is worn on top under the main body of it. bearing shagged. i need you to check the rod length which i take to be 120mm centre to centre. i'm 90% certain it's 120mm.

you can PM uno in norway as we went right through this and i may have let him know as we went.

i can't quite make out what happened but at a guess i think that the two screws that hold the cam sprocket were ok but that the baby stopper bolt broke - right? well when you rebuild with the new decomp you must remove this baby bolt and let the decomp hit one of the two sprocket bolts. you'll need a complete rod kit therefore and i do a special complete rod kit with pin and bearing for £180 plus £30 for a special little end bush.

you need to check the little end very carefully for wear, it's the little end in the 600s that knock the big end out. and unfortunately they let the gudgeon pin wear as much as the little end. why i don't know....

you'll need a steel sprocket if the alloy one looks at all iffy. i have a used one. i would change the mains for sure while i was there. you'll need the engine down to be 100% sure whether you have 6205 roller or 6206 ball. i think it's 6206 ball, maybe dezduster/oyk/ned et al can help you?

i do the best camchain - IWIS at just £30. if you haven't seen my stuff then go to ebay.co.uk and have a look or at my web site (see my sig).

i have a used selector drum as well if you need it. i've got everything.

regards

Taffy

i think it's 6206 ball, maybe dezduster/oyk/ned et al can help you?

Click to expand...

yes

and i had a wiseco piston in my 98 400. i have never seen it in anybody's catalog, but if you phone wiseco directly, and get the nice lady i spoke to a few years ago when i ordered new rings, she can prolly set you up. the rings weren't too expensive ($38 to my door). don't know what they get for a piston.
(sorry for the hijak, denny. .... eric :wink: )

thanks taffy and ned....i looked on wiesco's site and there wasn't anything listed at all for husaberg. I have their number so i'll give them a call have also talked with j e pistons waiting to hear back from them. they think they made a set of 4 for someone, but they can't remember if it was for a 400 or a 450. they are gonna check their invoices.
believe it or not this may force me to buy a new berg....can get 08's at a really good price. so now i am contemplating that. I work at att and our contract is up in april and thats coming into play too. I didn't mean to offend you taff about ebay, i was refering also to myself knowing the tolerances of the parts I may need. would trust someone from this site and a company, but the guy who just bought the bike to part out and wants to get rid of it, i'm a little leary about. I am going to replace the con rod and bearings with new. on the mains I called the dealer and he gave me the price of them but didn't see 6205 or 6206 in the part number out of the catalog or on the puter, looked at the mains and they seem fine, but i agree the case is split and now is the time. looks like only thing i may not replace new now is the piston unluss i can find an after market one. Still gonna look for one. if i have any questions i'll post here.......i downloaded the manuals here so that should take care of a lot of them i have.
thanks
Dan

:angry: :angry:

OBE (order of the british empire)
i left you a bit of a challenge, you know, a teeny bit of work, a small effort. just to see if you were as lazy as i think you are. you'll be pleased to know that you are.

ned's on to me and i think he knows i have a pet 'anger' (not hate) and who can blame me???? i mean, you can take a horse to water right?

however, i still get schadenfreuder and that's always a pleasure and i can relax happy (although slightly poorer) than when i started on this thread.

lets try those keys again for him shall we ned?
p-o=u=n=d=s=t-o-d=o=l=l=a=r=s



regards

Taffy

:lol: :lol: :lol:

The last time I rebuilt one of my early bergs (98 Fe501) I just took the bearings to my local bearing/belt/seal shop and they crossed everything to SKF C3 and it was less expensive than OEM. I found that the original bearings from the engine were all made in China and Korea anyway.
I didn't replace the shift drum bearings, but did all the rest just because.
the output shaft seal is 30x42x7 and the left side crank seal is 30x52x7. I couldn't find a non-OEM source for the right side crank seal (magneto side) so i ordered a stock 10x18x4/4.8.
This engine was overbored to 520, had a KTM piston in it and was e-start.
So just pop out the old bearings and head on down to the local NAPA (or equivalent) auto parts shop and they'll fix you up.
the early engine is very straightforward to work on.
The gaskets and stuff are easily obtained from any one of the usual berg sources.

Thanks Dez. looks like everything is going to be new except for the piston. I haven't knocked the mains out yet, but when I do I have a NAPA store right around the corner. I'm going to fix the 99 up and hopefully get an 08 by April. My dad is just now expressing an intrest into going offroad riding. He's 68 and mostly rode his gold wing around, never showed an intrest to offroad. So i'm gonna fix her up and when i get a new one this 99 will be his to ride. Yeah I know.....giving the old man the piece of crap !!!!!! LOL. Thanks again for the tank and shrouds 2 or 3 years ago. And yes taffy you got me.....funny thing is tho as I was typing the original post I was thinking to myself, I need to watch what I post in case taffy responds.......LOL. IT'S ALL GOOD! Anyway thanks to everyone at this site as it makes owning an older berg easier. especially when your a weekend mechanic.

our local KTM dealer just picked up husaberg. so now i can get parts easily. before i would call sportsman in vegas and either order the part and have them ship it to me or get a KTM part number and go to the dealer who now sells bergs and order the KTM part. I haven't replaced any bearings since i had the bike, but now it's time. perhaps i'm wrong about cost vs worth as this is recreation for me, but my disposable income right now is down, so i am looking so save some cost, hence doing some of the work myself. not trying to harm the local dealer, but $450 for a piston?