Seized

Cannot believe it. First, the bike is a 2004 Husaberg FS450e with about 3700 miles and around 90 hours. I bought it about 400 miles ago and so far its been great. Will start first or second kick most of the time and not had any problems (apart from speedo playing up but that will just be a bad connection I think).

The bloke I bought it off said he had changed the main bearing to ball race and it all seemed great. Since then I've realised he was hiding a bit. The chain has obviously broke and took part of the chain slider and in the book he's wrote about fitting a new piston but never mentioned it when I bought it (and we were chatting for hours).

Now, riding home tonight (done about 15 miles, riding was not too hard) slowing down for some lights to turn left going down the gears and as I pull the clutch in the engine stops dead so I knock it down the gears with the clutch in (didn't let it out at all since the engine cut) and pull over. Try turning it with the electric starter and it won't move it at all. Try the kickstart and that's not turning it at all with or without the de-comp lever.

Start pushing it home and try turning it over with the started and after about 40 minutes of pushing, it turns the engine VERY slowly. Only turned the engine over once in total as I don't know if I'm causing more damage.

Anyone know what it could be? I'm gonna strip it down tomorrow hopefully and see whats happened.

Got a Rino pipe fitted with 501 headers and the bloke said he 'gas flowed' the head.

Please help me out. Thanks, Carl

So far I've only managed to get as far as draining the coolant and oil (like to take my time). The sump magnet had loads of swarf on it though which has got me thinking what it is. Someone else has said they had a similar thing happen and the engine would only turn slowly because the cam chain had snapped meaning the valves were closed so it wouldn't turn over. I wouldn't of thought there would be any swarf (well, big chunks of metal) if a bearing had failed.

Carl

Finally got round to getting the covers off and seeing whats what (anyone else struggle with exhaust springs without the proper tool?).

Under the clutch cover everything looks fine. The cam chain doesn't look broke but has about 10mm movement in the bit you can get to under the cover. Not sure if that's normal or not though.

There's no play in the flywheel at all.

Took the valve covers off and the intake valves are 'up' and the exhaust valves 'down'. There's play in the exhaust valves and the intakes are solid.

What next?

Thanks, Carl

Does it need to be TDC to get the rocker cover off?

Tried to get it to TDC by turning the fly wheel (had to turn it backwards because otherwise the nut unscrews) but it was VERY hard to turn and would make a loud crack noise (did it twice in total) so I've stopped trying to get it do TDC now in case I'm doing more damage. The clutch cover was off while I was trying it.

Carl

Thank you Cypher, you have just made that much easier

Carl

Yeah I checked to see which way it should be turning by putting it into reverse and moving the wheel. When turning the flywheel clockwise though the nut came loose.

Carl

Got the rocker cover off now. Everything looks fine to me but I don't know what I'm looking for. All the springs look ok to me.

What's next now?

Thanks everyone for your help. I wouldn't know where to start without this place.

I've emailed Dave at DCR, just waiting for a reply now. I've asked for a quote to do all the work that needs doing at 90 hours including all the bearings and a few different prices with different scenarios with what could of happened. Give me a two stroke any day lol.

Well Dave has emailed me back. He recons its the main bearing. Said strip and rebuild is £180 £80 for the bearing kit and £30 for gaskets so I'm looking at £290 as long as he doesn't find any more damage. Considering just sending it off as it will be much easier to sell with that all important receipt.

Carl

Yeah I think I'm gonna send it off and I'm sure they will know what bearings and whatever were in there. He will phone me beofre he does any work on it first so I can ask then.

Now just gotta put it back together and get the engine out. Flicked through the manual and it doesn't look too difficult.

Anyone got an idea of the weight so I can figure out if its cheaper to post it or drive up?