Intro - Hoge's Husa (Australia)

interesting thread from DBW

Stuck Swing arm Bolt - dbw - dirtbikeworld.net Members Forums

I managed to track down the original owners of the bike this week. It took a little detective work but I contacted him on Facebook.

Confirmed it was his father's bike (and that he is 75 this year). Bought two bikes brand new in 2002. It has something in the vicinity of 1000 to 3000kms - the speedo cable was torn off and they put the Acewell digital on it.

They still have the other bike.

He also sent me this photo - and the accompanying story was "Like a week after buying it, dad followed me across a dam, I was on a pw50 so didn't even make a mark".

aaron said:

Still having difficulty with the swing-arm bolt.
(wheel off and shock undone so no tension on anything)

I used a section of pipe with a flat plate welded to the bottom.
Layed the bike over so the bolt was over the centre of the pipe and the pipe was hard against the frame.
Gave it a massive belting with a BFH.
It didn't budge.

What's next? Do I have to make a one-off custom hydraulic press out of steel and a car jack? Or a big "G" clamp? Heat?

Make a slide hammer like this?
https://www.youtube.com/watch?v=OcESnOmU5Y0

:cry: I just want this donk out of the frame.

Click to expand...

This might be a bit personal, but how big is your BFH? Does it require two hands to swing? If not, it might not be big enough...

My swingarm bolt was incredibly stuck too. I had to hit it really, really hard to get it out. I feel your pain.

I have a range of BF hammers. Up to Really Big F'n Hammers - ie: the sledge. But I'm fairly hip to what will budge something and what will make a mess. Particularly when I needed to hold a pin punch in one hand and swing with the other.

This is the Macpherson strut tool I decided to modify. I have one more job to do for a friend this weekend (replace her front shock absorbers) and then I can turn this into a swing arm press.

Just a few more pics.
1. Is this the factory installed piston? (part number visible 15100-5) No marks on it. No slop or twist.

2. Australian ID plate for Road Registration.

3. Engine serial #5012237 (model 501 year 2002 bike 237) - given this serial, can anyone shed some light on the engine internals, particularly the counterbalancer bearing/tooth profile before I split it open?

4. Going by the blue colour it looks like the SEM ignition has been reconditioned already.

5. Extra battery in a fabricated alloy sheet box. Neat job, only let down is that block of wood.

that is the OEM piston and as you may have read in a post near here, getting spares right is hard work! I have rings for them though. I think!!!!

the balancer assembly needs two special bearings which again i can do for you OK?

I've seen that blue hue before but I'm not sure what it signifies?

regards

Taffy

Cool bananas! I reckon a set of rings and a bearing/pin kit.

I haven't seen a pic of the balancer so I'm not sure what the bearing looks like. This was the mod that I was told about by a local last week. I only just read the thread on it today.

The shop I was referred to was Valley Force Husaberg in Lillydale Victoria. Although it appears they have closed. If anyone knows those guys I'd like to be put in touch.

Also, quick question, part 800.36.020.044 - cylinder head. Ad says removed from a 2004 fe450e. Will this fit the 2002 fe501? Just noting mine has a 95mm cylinder and not sure of compatability between different capacity engines. My combustion chamber appears different. But this comes with what I assume to be an "08" cam.

I think the heads will swop but it is head and rocker cover COMPLETE you are looking for? you'll also have no oil feed to the head.

Taffy

Mine is fixable (with welding the rocker cover, new valves, new springs, new cam etc).
This is already welded up, appears in ok condition and has an 08 cam.

No oil feed could be a problem though.

oil line to the head ?

post #3

http://husaberg.org/tech/18593-husaberg-fe-550-3-rebuild-project-3-angle-valve-seats.html

I ran one to the exhaust rocker pin (08 head)

Little bit of progress to report:

Ebay has been full of bargains lately. Picked up a KTM EXC rear fender with indicators (turn signals) for $20 within 5 mins drive from my house. Previous owner of my bike had broken the originals and fitted small amber lights intended for a truck or trailer. It was a neat job and less prone to damage in the bush but non-compliant for registration so I was very glad to find replacements cheaply. I rent factory space from a friend that runs a Vehicle Inspection (Roadworthy) business. After installing them my buddy said "Nice job, but I would have written you a roadworthy anyway".

I luckily found a replacement for my cracked rear yellow plastic fender in good condition on Trademe.co.nz picked it up for $55 NZD now just waiting on it to arrive. Then went to the local tip which runs a recycle shop and found a black KTM/Acerbis front fender which they gave me for $3!

Yesterday I scored a 2005 fe650 complete head and cam (which I assume is the "08" cam). My earlier post referred to an ebay auction in the USA for one that had been repaired but I got lucky with an Australian listing for about half the price.

I also scored the front and rear plastics from the same ebay seller although they are the reverse colours to my bike so I'll mix and match if need be. He also has a B&B bash guard going cheap which I'll pick up next week. Also tempting to get the Akropovic system but I can't justify the spend on that just yet.

Narrowly missed out on a KTM steering damper for $260. Decided I MUST have one for safety. I'd prefer a Scott's/Öhlins just to keep the bike as Swedish as possible. And Steg Pegz.

Been picking up a bit more riding gear too. My work colleague's husband has lost about 40kg and had to buy all new gear so I got his Rallycross II jacket. Just need boots now.

Once this head arrives I can start ordering parts for re-assembly! Getting excited.

I'm a fan of the Scotts, have have them on both Bergs. But the old 501 gets little use so its one migrated to a DR.

One of these Universal Motorcycle Steering Damper Stabilizer | eBay turned up in the mail the other day, as yet untested, but looks and feels identical to the original, so I have another ordered for another project.

I'll probably disassemble it and replace the fluid with known stuff and it'll do the job.

I can't really recommend them yet, but at the price I couldn't resist.

that looks awesome steve thanks for the link.


does it have return to centre damping like the road model scotts ?

im using one (road bike scotts) on my 650

Yep, both ways, but as I said, as yet only unpacked so actual performance TBC.

It feels a bit stiff, but that's just playing with it, and will likely loosen up a bit with use, but also one reason why I think I'll change the fluid. Superfically, the only difference from the original is the lack of an engraved moniker. Externally, its otherwise identical, looks the same as the original, so if inside and clearances match up, its a bargain.

If in the end its not great, well, you've been warned

PS, also has adjustable sweep like the original.

I'll grab one of those next pay! Would be easiest to just get a Scott's mounting kit and probably go for a weld-on.

I suppose I should add that the dampoing both ways is best suited to open fast going, sand etc.

The non damping return is better for terrain like single track where you want to turn quickly.

Horses for courses etc.

aaron said:

I'll grab one of those next pay! Would be easiest to just get a Scott's mounting kit and probably go for a weld-on.

Click to expand...

not pretty but it works

I had hoped to get some pictures to go with this update but my phone was flat last night by the time I made it to the factory where my bike is stored.

Recently I've purchased more bling parts for a bike that as yet doesn't run. Just can't help myself.

Roc Stompa damper mounting kit $1. (yes $1.00)
1x yellow rear plastic from New Zealand $80
1x blue rear plastic and 1x yellow front fender $50
Acerbis LED Vision head light $20 (this is a $200+ unit new!)
B&B exhaust shield (new in packet) $20
EGO Barkbusters $80
Workshop/Owners manuals for the WP suspension $20
Complete cylinder head from 2005 fe650 with "08" cam and black tensioner blades$300


In an earlier post Taffy mentioned there would be no oil feed in that head. At the time I thought that was a reference to the external oil feed I was intending to add. However, now I can see what you mean - there is no oil gallery in the corresponding location.

I assume there must be an oil gallery elsewhere perhaps running through a bolt hole? Will I be able to have this drilled for the 501 located oil feed or is this head swap just not possible? Going to need to address this before I go spending on parts. The 501 head has some minor damage so it will be a toss up between which is the more economical to repair or modify.

The other thing of note is the different shaped combustion chamber. Hard to say if this will have any effect on compression ratio.

I haven't removed the valves or conical valve springs from it yet although they don't look as though they are recessed into the seat (or "tulipped" as some of you say). The 08 cam is in excellent condition and was the primary reason I bought the head. The ADC stopper looks as though it has very slightly dislodged and was at risk of coming out (will mig weld that pronto as I've seen others do).

I also made it out to the nearest Tool Hire and checked out the Enerpac hydraulic port-a-power. They rent it for $110 per day. Had to size it up before making the press frame but at least I have salvaged some scrap steel for that job now.

The Roc Stompa damper kit came cheaply at a buck but I can't be certain if that ebay damper is going to fit it - haven't yet measured it properly. Although it was advertised for a Husaberg the collar is just slightly undersized so I'll have to send that off to be CNC machined for a good fit or just move to a weld on. I'll also need to change the bar risers to match the upper bar clamp which has two bolts per side whereas my bike has four bolts per side.

I'll be excited to get the replacement plastics on the bike. The Acerbis headlight looks mean as! It was mounted on a Yamaha but never wired in. I splurged on a proper Deutsch crimper and as much again on a connector pack a while back so should be a solid wiring job

My other wishlist items:
Steg pegz which are made locally - retail about $160
Radiator guards
Radiator fan
Bash guard


Let me know if there's a bike getting wrecked with any of those bits!

Looking good,

I see a rad fan on your wish list. Should you find a fan? I would be pleased to contribute to this project and be able to supply a thermostat switch and the harness assy as I just found one the other day when looking for a connector for a other forum fellow Husaberger
I would require the cost of shipping if you want it. but no charge for the new part and harness. Let me know if you can use it or it helps?