This site may earn a commission from merchant affiliate links, including eBay, Amazon, and others.

Pictures of engine overhaul 200H

K

Karl

Joined Apr 2004
18 Posts | 0+
Norway
My FS650E 2001 mod has now got exactly 200 hours on it. All the riding has been done on tarmac road.

So i opened it up to change all the bearings, but ended up changing a lot more.

New exhaust valves, new con rod, new clutch basket, new starter gear, new de-comp gismo.

Old piston and piston ring were re-used. Gap on the piston ring was 0.35mm.

Her is some pictures of what i found.

Piston, measured to 99.95 mm.
Liner
Main bearing, please note that the inner race has slipped on the crank shaft.
Old con rod
cam shaft
de-comp. If you look closely, you can see that it is worn.
More pictures.

Karl
 
Damn dude,

Other than the broken starter gear, and chipped tooth on the clutch basket that thing looks pretty darn good!

Glad to see you got so many trouble free hours out of it!
 
how was your bike running at 200 hours , was it blowing smoke or burning oil . did it have any funky rattles , did it have excess vibration ect ect .
the reason i ask is my 650 is on 128 hours , goes hard and i am getting ready to split it down the middle. so long as it shows no sign of illness 200 hours is when i plan to 'operate on the patient ' .
 
It was running just fine, no smoke, normal noise level.

The reason for this overhaul was actually that its winter time, and lots of snow. So i figured that its better to do it now, than in the summer when the sun is shining...

The only sign of wear i have found was that the left main ball bearing inner race hade a loose fit on the crank shaft.

The old exhaust valves was also in good condition, but replaced as recommended by husaberg dealer.

Keep in mind that i had all ready the modified engine, with the new counter balancer and rocker arm bearings.

The cam shaft chain is on the 3 click from the "end"

The broken gears are from a major back fire i had when i was almost out of gas, and still had the solid starter gear.

Here was the total cost:
All ball bearings 250$
Gasket kit 200$
Exhaust valves 120$
New con rod kit 450$ (1mm longer, recommended to be changed by dealer)
Fitting of new con rod 50$
Total 1070$

Lost of money, but now i have a "new" engine. :D
 
thanks for your reply karl, if it cost you a $1000.00 it will cost me $1600.00.
money well spent . :)
 
Hi Karl!

I am very surprised to see that your intake valves are good enough to reuse. Mine at 150 hrs were severely worn. Much worse than the exhaust valves. My exhaust valves could have been reground, but I replaced them just the same. I also find it interesting that your piston is so healthy. All this could just be from the fact that you stay on tarmac.
A very good report. Gives confidence in the brand and good maintenance.

/Peter
 
I use only full synthetic, change oil after 10 hours.
Lot of the running hours are in fact highway use, from A to B.
My personal record is 6 hours strait, on the highway. That was boring and a real pain in the ***.
My average speed on the highway is 80 to 120 km/h. When I run 120 km/h there its a lots of rpm.

I have also practiced allot do wheelie and stoppie's, lots of max power/0 power/hard landings. But i have not done long wheelies, becurse I always fall down :cry:

When i finally find a nice twisty road, I do not drive gently to save to motor, I use it hard, but no abuse.

Karl
 
Is that the normal price for a complete gasket kit?I find $200 pretty steep for a bunch of gaskets...
As for the bearings,I get a 60% discount from work at SKF bearings \o/
Good to hear your bike kept well so long.
 
thanks for the reply karl, looks like your use of the motor and maintenance schedule is close to mine . my berg is set up for enduro , but when it was new it was a supermoto, and with a full akrapovic system hit just on 200 klm per hour flat out. motor absolutely screaming,i was very impressed.---bergs are strong and reliable
 
I agree that the prize for the gasket kit is a little expensive. In the kit there is, new head gasket, 5 oil seals, 4 oil seal for the ex/inn valves, cluth house gasket, valve cover gasket, and plenty O rings.

Regarding the bearings, the one that really pull up the prize is the two bearings for the counter rotation weight. They are standard bearings that is grinded down from the(KTM/Husaberg) factory to narrow the width. 60$ for one.

Karl
 
When my bike is ready for an overhaul I will grind the new bearings myself at work. :lol:
 
Nice to see that the berg could last for 200h...
Mine has got about 155h on it now and i don't have any problem.
I also have new/upgraded rockerarms/bearings, so i hope it wil last for another 50h befor i have to splitt the beast open.

Og hallo til deg karl=)
 

Similar threads

A
For Sale For sale 04 and 08 FS650e with a lot of goodies
Replies
11
Views
3K
Galanius
G
A
For Sale For sale 04 and 08 FS650e with a lot of goodies
Replies
1
Views
521
MisterKaoz
M
S
Spencer's fs/fe 650
Replies
5
Views
2K
o6550
o6550
E
Solution to damaged inner clutch hub
Replies
21
Views
6K
ORANGEBERG
O
Sandtorven
2001 FE650E with tuned engine - Need some expertise!
Replies
0
Views
989
Sandtorven
Sandtorven

Register CTA

Register on Husaberg Forum! This sidebar will go away, and you will see fewer ads.

Recent Discussions

Recent Discussions