Problem with choosing right mods for my 2002 fe 501

Urban · Mar 29, 2015

Hi

I've recently took my 2002 fe 501 apart to check everything, engine is off the frame i'm going to take it apart probably tomorrow .
Bike has 3500km on the counter(?), it was in some guys garage standing for 4 years thats for sure .
I've done some searching and not sure what mods are worth doing I defiantly don't want spend that much money
to make every of them right now but on the other hand i want this bike to be reliable so asking for your help to choose right mods:

1. i have original valve springs and i think i will live it alone do they break in like 10% of the bikes or more like 90%? i've read they break like 200+ hrs -one of the rocker bearing was replaced

2.bike doesn't start on the restarter (cold or warm)
i have cleaned the starter and replaced the sprague clutch dind't helped- bigger starter from 650 or a auto deco upgrade ?
what i have to do to put the newer auto deco in my cam ?

3. Do i have to do any changes in cylinder head or in engine to put the newer "black" cam chain slipper or its fits just like that ?

4.I think if the balancer will be fine i will live it alone- what do you guys think about single bearing balancer in 501 is it going to last some reasonable hours ?
i dont want to take it apart for 6 months again

5.And the last but not least is there any way to check if parts are crossover with KTM or newer husaberg parts if in my 2002 parts manual i still have husaberg part numbers

jmscrttndn · Mar 29, 2015

Urban said:
5.And the last but not least is there any way to check if parts are crossover with KTM or newer husaberg parts if in my 2002 parts manual i still have husaberg part numbers

Yes, put a part number into a search engine on a KTM dealer site and it will come up with the comparable part. Try to search on Munn Racing (be sure to select "OEM Parts" rather than "Hard parts" when searching.

Also, I always remove and periods from the part number. For exmaple,

800.123.345 becomes 800123345

Note: I ASSUME this will work for 2002

aaron · Mar 29, 2015

Urban said:
Hi
I've recently took my 2002 fe 501 apart to check everything, engine is off the frame i'm going to take it apart probably tomorrow .
Bike has 3500km on the counter(?), it was in some guys garage standing for 4 years thats for sure .
I've done some searching and not sure what mods are worth doing I defiantly don't want spend that much money
to make every of them right now but on the other hand i want this bike to be reliable so asking for your help to choose right mods:

1. i have original valve springs and i think i will live it alone do they break in like 10% of the bikes or more like 90%? i've read they break like 200+ hrs -one of the rocker bearing was replaced

2.bike doesn't start on the restarter (cold or warm)
i have cleaned the starter and replaced the sprague clutch dind't helped- bigger starter from 650 or a auto deco upgrade ?
what i have to do to put the newer auto deco in my cam ?

3. Do i have to do any changes in cylinder head or in engine to put the newer "black" cam chain slipper or its fits just like that ?

4.I think if the balancer will be fine i will live it alone- what do you guys think about single bearing balancer in 501 is it going to last some reasonable hours ?
i dont want to take it apart for 6 months again

5.And the last but not least is there any way to check if parts are crossover with KTM or newer husaberg parts if in my 2002 parts manual i still have husaberg part numbers

Hi URBAN, I have the same bike (engine serial #5012237) in Australia.
The top end in this bike let go (cam roller bearings, tappet, broke timing chain).
I'm looking at doing the following:

Add an oil feed line from the filter cap to drip on the cam roller bearings.
Later "08" cam and de-comp.
Kibblewhite valves/valve springs.
Later cam chain guide

Already have a Keihin FCR 39 carb fitted. Bottom end seems ok however the balancer was mentioned to me as a worthy modification to dual bearing. I may put a rod kit through it as I'm not sure of the hours on this bike and I just want it reliable for years to come.

Feel free to share your learnings with me as I'm new to Husabergs. I have a thread in the introduction section.

husabutt · Mar 29, 2015

I would definitely consider doing the balancer as it is probably your weakest link.

Go to Husaberg.com and download the 2003 workshop manual part 4 and read how to determine if your motor has the gear tooth profile of a 2001 or 2002.

If it was built as an 01 the updated double row balancer assembly is $ 584.31
If it was built as an 02 the updated double row balancer assembly is $ 409.69

The 01-02 single bearing is $111
The double update bearing for the update balancer is discontinued.

Taffy has had some made. Taffmeisters - Husaberg, KTM, Husqvarna, Gas Gas, dirt bikes - servicing, tuning, rebuilds, parts
I think you could use his double bearings in your single bearing balancer. I am sure he will chime in here and advise.

The counterbalancer spins in the opposite direction of the crank. If the motor is spinning at 7000 RPM's the balancer bearing is spinning at 14,000 RPM's.

If you want to eliminate the possibility of the CB failing you can remove it and have your crank rebalanced. Some have done it and did not like the vibration.

Urban · Mar 30, 2015

jmscrttndn said:
Yes, put a part number into a search engine on a KTM dealer site and it will come up with the comparable part. Try to search on Munn Racing (be sure to select "OEM Parts" rather than "Hard parts" when searching.
Also, I always remove and periods from the part number. For example,
800.123.345 becomes 800123345
Note: I ASSUME this will work for 2002

Thanks for help jmscrttndn, i was looking for some magic trick to turn the husaberg part number into ktm number ( :banghead: )
but now i see it's not possible. Although I found some useful topic on subject of crossover but instead of bandit shop
i had to use some other cause bandit gone trough
some changes i used "makinaparts" instead to check what models of ktm part is fitting
http://husaberg.org/mechanical/8904-ktm-crossrefrence.html

I used munn racing site and this topic have been a little bit useuful too http://husaberg.org/service-manuals/17596-useful-crossover-parts-2007-ktm-525-rfs-parts-list.html

Hi aaron, nice to hear from another 2002 501 owner. I
dont know if im going to change the valves and springs
but i found that hacker33 used a "59036030010 VALVE KIT 400-525 SX/EXC 99-7 " for his fe 450 and if im going to change them that's what im going to use
( kibblewhite has good opinion but shipping to my country will last "centuries" and ktm parts are aveible quick) .
I would like to try a "08" cam but its hard to find in a good
price, close to where i live in a short time.
buying upgraded autodeco from taffy and machining my original cam for it its my best option ( or not but i don't see a better one )

Husabutt thanks i will definitely consider changing balancer now for double bearing
Looking forward to any other opinions about whats worth doing

Taffy · Mar 30, 2015

boys

all the bikes except the 400 and 470 had twin ball balancer assemblies. so you already have double row bearings in your balancers OK?

I do the bearings for these
I also do the modified tensioner blade
and the sledge mod
and the DVSK

if you go to an 08 cam be prepared for your jetting to be miles off - sorry but that is the truth of it with the dell orto, however, Aaron should be OK with his Keihin FCR fitted as the figures are well nown for this.

regards

Taffy

Urban · Mar 30, 2015

Hi taffy
I'm probably not going to buy a machined bearing it's not going to last long or if i'm going to use one i'm probably going to make it by my self or find someone to do it here.
Is your tensioner blade modified in any way or its just part from newer bikes?
I have just bought new sledge for my bike from husaberg.
As i said about valves i'm going to stay with ktm ones if it's possible .
I realize that if im changing the cam i have to change the fuel settings- thanks for remanding anyway

What i have to change in my cam to fit your newer autodeco kit ?

husabutt · Mar 30, 2015

Taffy said:
boys

all the bikes except the 400 and 470 had twin ball balancer assemblies. so you already have double row bearings in your balancers OK?

210 195-01 Counter balancer 400 -01
210 255-01 Counter balancer double bearing 400 -01

210 196-01 Counter balancer 470/501/550 -01
210 197-01 Counter balancer 650 -01
210 257-01 Counter bal.double bear. 470/501/550/650 -01

Taffy please see attachment.

So the question of the day is can your double row CB bearings be fit into an originally fitted single row CB?

Taffy · Mar 30, 2015

there are no mods required for the later adc to fit the later cam. my blades are modified.

Erik, I have only ever seen single bearing 470s. I have one here this week and it is single row again.

regards

Taffy

bushmechanic · Mar 30, 2015

urban, Ausberg had some great pics in the gallery

http://husaberg.org/mechanical/17214-counterbalancer-bearings-definite-thread-2.html

regarding fitment etc see heimirs post #15

http://husaberg.org/husaberg/17409-mechanical-whining-noise-2.html

husabutt · Mar 30, 2015

Taffy said:
there are no mods required for the later adc to fit the later cam. my blades are modified.

Erik, I have only ever seen single bearing 470s. I have one here this week and it is single row again.

regards

Taffy

The double row would be the factory update part.

By chance have you ever tried to install your double row bearings in the single bearing CB ?

Taffy · Mar 31, 2015

Hello Erik

I've 'kind of' tried. the single bearing unit has a back line rim to stop the bearing falling out the back and a circlip at the front. you could grind the backwall out and remove the circlip but then you would need a central groove to put a wire clip in and there isn't a groove so that would have to be machined.

in the meantime, the bearings never go anyway! rumours created by my (then) dealer that I got my bits off of were, now proven, to be untrue.

the single row can get rid of any crap out the sides and it gets flung away whereas the double rows have a serious problem if crap should get between the two rows - how does it get out.

far from single rows being the weaker design, I think that there's a lot to be said for it. don't fix it till its broke is the saying I believe!

regards

Taffy

Urban · Apr 3, 2015

Thank you all for responses.
Balancer problem solved itself i've split the cases and.......
I dont have a balancer at all ! so i'm going to order hole assembly.
Your advices clarified me a bit what i need to do- i'm going to start
another thread about rebuild
thanks again to all of you

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