Seized 02 FX470.. might need a little help (pic heavy)

Rot Box · Aug 28, 2016

Hi it's Rot Box, you've probably seen me on the ATK boards. Today I finally landed a Husaberg

I bought it from the original owner with a seized engine. Not sure how, what or why it seized but the price was right and I needed a project.

Anyway I figured I'd take you guys along. I might need some help as I dig into it further. Right now I'm trying to figure out what the heck happened haha!

Good looking bike from a distance

Under the plastic the thing was filthy. Oil all over the engine and I think I figured out why. Duct tape did not fix this broken head cover vent..

Plugged off coolant port:

Sump screen was nearly plugged off with shavings. Filter didn't look great either.

Smash101 · Aug 28, 2016

That's neglect and abuse, I would report the previous owner

Rot Box · Aug 28, 2016

1... 2... 3... Uh?? Where's 4?!

Here it is.. Jammed between the cam sprocket and the cylinder head

I pulled the head off. For the most part everything looks good. The crank does not turn freely. It feels tight, but it binds up randomly as I turn it. Going to pull it down further when I get more time.

(I normally clean engines really well before opening them up. I figured I'd pull this one down all the way so I'm not too worried about dirt/debris getting into it right now)

Any idea on what this piston is? Looks forged and high compression.. Guessing it's not stock.

Rainerio · Aug 29, 2016

Please Smash101 tell Me where to do the reporting. I've got at lest three hack mechanics I can turn in and it was on Berg's BLASPHEMY!!!

ElSnorro · Aug 29, 2016

I have rocker arms for sale if you are intersted.
Used but good.

looks like a wossner piston

Smash101 · Aug 29, 2016

Rainerio said:
Please Smash101 tell Me where to do the reporting. I've got at lest three hack mechanics I can turn in and it was on Berg's BLASPHEMY!!!

I think we might have to start our own organisation for all abused bikes.

1,2,3 that's a weight saving design, it also mellows the power.

Smash101 · Aug 29, 2016

Rot Box, what's your estimated cost to have it back up and running?

Rot Box · Aug 29, 2016

Thanks everyone. I forgot to mention this bike was used for desert racing its whole life so it was definitely rode hard.

Smash, I'm not sure on cost at this point. Part of me is hopeful but part of me is expecting the worst. I just hope it doesn't end up being a boat anchor. I'm going to keep pulling it down to inspect everything and make sure nothing else is destroyed hopefully I get lucky.

ElSnorro, definitely interested I'll shoot you a PM. Thanks!

Rot Box · Aug 29, 2016

I was happy to see the Dellorto carb. I've always liked these.. no pumper though but that's ok. Where it's an 02 I'm guessing it has the SEM ignition? I've always hated those haha.

I definitely have a lot of reading to do. Being my first Berg I'm still learning. I'd like to improve/upgrade things where I can while it's apart.

Rot Box · Aug 29, 2016

Found it!

I'll be honest.. I have no idea what this is. Obviously the gear drives the water pump but I'm not sure why there's a bearing here and what looks like a counter weight.. Either way it exploded and sent bits though the engine. I wonder how that is related to the rocker arm breaking...

Do you think the crank is trashed or can I remove and replace this portion? Looks like I need at least a new bearing and gear so far.

The piston has light scoring on it. Upper rod bushing should probably be replaced. I can't help but think I should send this crank out and have it professionally rebuilt and balanced. I noticed Taffy offers new rods for this one.... What do you guy's think?

On that note the transmission and clutch side look very nice. A few bearings with debris in the that will get swapped out. There was case sealant all over the place. I'm thinking whoever had this motor apart likely used too much.

Oh and I need a flywheel puller (it is the SEM.. ugh). Any idea on the size and where to find one?

Thanks a bunch!

ElSnorro · Aug 29, 2016

buzzetti has a flywheel puller for SEM
m26x1.0 (inside thread)

like this
Extractor -BUZZETTI- M26 x 1,0 (inside)- (type clutch cxtractor Vespa Smallframe) - Scooter Center Vespa, Lambretta and modern Scooter spare and tuning parts

Rot Box · Aug 30, 2016

It's the counterbalancer haha.. I've never seen one like this before! I'm guessing they work pretty good? So the bearing on mine was a single roller and I'm thinking the newer models were a double roller? Single does not seem like a good idea in this application hopefully I can upgrade it..

Water pump gear is shot. Counterbalance and bearing are shot. Crank looks like it's salvageable but I'm thinking I had better send it to a professional to have it worked over.

The rod looks rebuildable.... Should I replace it just because? :unsure: I'm learning a lot. I need to slow down a bit this was supposed to be a winter project LOL!

tourist · Aug 30, 2016

I'm just a muppet, but people like Dale Lineaweaver and bushmechanic advocate for removing the counterbalancer and balancing the crankshaft. Dr_C did it on his build too afaik.

Some info here: http://husaberg.org/mechanical/17329-balancing-80mm-650-crank.html ... and other threads! It's a fun topic to chase a bit.

On the 650 at least, people have been going for balance factor 62.5 I believe.

Rot Box · Aug 30, 2016

Thanks for the info Tourist. You know.. I'm going to send the crank out anyway to have it rebuilt and balanced. Getting rid of the counterbalance would save quite a bit of money. Not looking to cut corners/costs on this project but I wonder if eliminating it might be a good option from a reliability standpoint. I don't like the idea of having a single roller bearing here...

Hmm something to think about.

Taffy · Aug 30, 2016

rot box

I would first of all look at the feame number, 10th digit. is it a '1' or is it a '2'?

I would keep the balancer, most people do. Dale Lineaweaver was an out and out tuner racer. these things vibrate without one. you should not have had a ROLLER bearing. you should have had a single row ball bearing.

the revs are greater in the 400/470 yet they only get the single row balancer. if the crank never went - that would be fine!

Taffy

regards

Taffy

Rot Box · Aug 30, 2016

Taffy said:
rot box

I would first of all look at the feame number, 10th digit. is it a '1' or is it a '2'?

I would keep the balancer, most people do. Dale Lineaweaver was an out and out tuner racer. these things vibrate without one. you should not have had a ROLLER bearing. you should have had a single row ball bearing.

the revs are greater in the 400/470 yet they only get the single row balancer. if the crank never went - that would be fine!

Taffy

regards

Taffy

Taffy thank you for chiming in

The tenth digit is a 2. What does this mean? And yes it is in fact a single row ball bearing not roller like I posted earlier haha.

From what I can see the counter balancer bearing exploded and took the crank bearings out with it. The inner water pump gear is trashed and so is the balancer gear and I'm guessing these parts are not cheap or easy to come by...

Rot Box · Aug 30, 2016

Thanks everyone for your help so far. I've been through a lot of bike engines in the past and this one is by far the most unique so there's definitely a learning curve for me

Right now I'm wondering:

Can I/should I upgrade to the dual row ball bearing balancer? I need a new balancer and bearing anyway..

Can I upgrade to a roller bearing on the crankshaft mains or do I need to stick with the ball bearings? (thinking longevity over performance)

And lastly is an 02 470FX worth putting this much time and money into? I knew it would be expensive going into it I just want to make sure I'll have a reliable bike for years to come. Are there any known faults with the 470's that I should be aware of? I'm not a racer... I've ridden dirt bikes my whole life but I don't ever ride competitively. Single track, two track and fire roads if that makes any difference..

Thanks again for any help or tips.

Andrew

Rot Box · Aug 30, 2016

Rot Box said:
Can I upgrade to a roller bearing on the crankshaft mains or do I need to stick with the ball bearings? (thinking longevity over performance)

And then I stumbled upon this thread (great thread btw!!).... http://husaberg.org/mechanical/17170-definative-main-bearing-thread.html

I need to slow it down a bit. Starting to get overwhelmed :unsure:

Taffy · Aug 31, 2016

your mains went first IMHO.

yes, stick rollers in.

the 2002 has the same primary gear system all the way through to 2008. the 2001 had different gears.

so upgrade at your pleasure to all 2002-2008 type stuff. there is a very slight difference in balancer assemblys from say a 400 or a 470 etc but I wouldn't worry about it.

I don't get involved in the definitive MBT because it is a waist of time argueing with some people. fact is stick any of the KTM/Husaberg OEM roller mains in and they will be fine. you just simply need to make sure that the crank is true and that you have 0.50mm of float.

it's well known on here what I call the 470 engine: the rat phuq engine. you'll need to build it with some skill.

regards

Taffy

bushmechanic · Aug 31, 2016

Skf mains still fail prematurely with "correct" end float

Ntns dont.

It's a simple fact orangerg brought to our attention.

Nothing to argue about

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Seized 02 FX470.. might need a little help (pic heavy)

Rot Box

Smash101

Rot Box

Rainerio

ElSnorro

Smash101

Smash101

Rot Box

Rot Box

Rot Box

ElSnorro

Rot Box

tourist

Rot Box

Taffy

Rot Box

Rot Box

Rot Box

Taffy

bushmechanic

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