510 Seized Engine Disassembly

So, the adventure begins. I purposely didn't put "Rebuild" in the title because I'm not sure I will want to put it all back together after I find out what's inside.

Background on the bike, it's a 2008 TE 510 with less than 2700 miles. I bought it mostly as a parts bike after the PO reported it seized during a trail ride. My goal is to learn more about Huskies and working on bike engines in general, in case my working Husky decides to go boom at some point in the future.

I removed the valve cover (these 510's have very little clearance up top) and got my first surprise:





Looks like something punched a hole through the valve cover. Looking inside the head it looks like one of the intake valve rocker arms is MIA, as in I don't see it anywhere in the head.

I'm gonna take out the engine and see where all that metal went.

This is going to be fun. I almost bought that bike. http://www.cafehusky.com/threads/2008-te-510-parts-bike.46946/

Ouch!

Only had time to wiggle the engine out of the frame today. Would have been a lot easier with the rear shock removed but I couldn't get the top bolt loose. I hust unbolted the bottom linkage and pulled the swing arm as far back as I could.



No time to dig in but I did find some treasure inside the intake port:

So here's a question. The head on this engine looks almost identical to the head on my 630. Rumor is that the 630 got its head from the 450/510's. So how come I can check my 630 valves every 3000 miles while this one ate its intake valve at 2700?

Then it begs the question, can I get a 630 head to fit on here and would it actually require less frequent valve checks.

My 510 09 engine got about 3200miles on it and the valve clearance hasn't changed at all since I checked them the fist time (about 3hours). So my guess is bad luck or maybe it was to little oil on it?
Anyways it's a simple engine to work on and I'd think the 630 have the same head, I've never compered the two, but I seem to remember they look exactly the same. Would download the workshop manual for it if you dont have it. Real handy to have.

If you dig a little deeper please take more shots

The carnage continues:

Missing Rocker Arm and Shim



Nice little piece of treasure found down in the head bolt hole



Then the head comes off:



And it gets worse



Where are the valves?



Found one!



This is a better angle



Cylinder looks surprisingly good



Two marks from the broken valves





So...how has your day been?

Holy SH#T!

Wow!

Amazing pics, thanks for posting them, looks like a casting flaw in the rocker arm.

No chance this bike will make 20k like yours did

Looks good. I say button 'er on back up and ride!

Seriously- thanks for taking/posting pics so others can learn as you plug away. Good work and good luck!

Eric

WOW.

Cylinder up is junk. That is insane.

Glad you enjoyed it

It's def been a learning experience for me as well. As I mentioned at the beginning, not sure I can or want to put it back together. Now, if I can figure out whether I can put in a taller 5th and 6th gear while I have the bottom end open, I might attempt it and make the bike a better dual sport, otherwise this bike will probably get put out to pasture.

Man, these pics are amazing to look at. Scary, but amazing, lol. Was it just lack of maintenance / neglect, or an internal flaw with the engine? Would love to have a parts bike to pull apart like this.

I would say it was from the opposing valves.

I'm also gonna guess the valve being punched up by the piston is what broke the rocker arm. But I'm not sure how the valves self destructed. As far as I know the valves were checked around 1,500 miles, oil changes on time, destruction happend with 2,637 on the ODO. PO said mostly easy trail riding, bike came to me with Shinko 700's, so probably wasn't doing much MX. Maybe a little too much highway to get to said trails? I dunno.

looks like the old swede 510 bikes with the 2 piece valves that liked to come apart. i bet uptite had piles of em.