09 TE510 Build

[antirich]

Been casually looking for a replacement to my beloved 07 SMR450. Main interest was a used TE310R, but came across a very well priced 09TE510. Bike is very rough, but just couldn't say no to the price (4300 miles and $2,000). The downside is an obviously leaking headgasket, and hopefully not much more. Either way, time for a full teardown to see what's there.

Picked up the bike; which is beyond rough. Had to keep reminding myself the low cost:

Off the trailer:

OK, ready to operate:

Lots of missmatched bolts. I'm pretty sure this engine has been worked on; water pump has been removed, derestricted and I'm guessing the head as well.

Looking a bit rough where it matters :-(

Down to the essentials. Overall, it took me about 40 minutes to get it to this level (including the exhaust removal); amazed on how easy it is to field strip one of these bikes. The pipe on my Triumph takes longer than that to remove.

Don't know who these guys are, or if they're in business. But it is a local number, and maybe they did some engine work to it as well:

When finished, i hope to get it looking more like this :-)

I'm hoping to keep the Husky as a low cost project; combing the classifieds, Craigslist and eBay for the best deals. No rush, but would be nice to get it up and running by end of March.

Originally, I was thinking more of a full SMR build, but I'm finding some nice off road places to ride around NJ. Maybe a little bit of both, who knows.

So far, I thinking my needs are:

-Headlight and plastics (all are crap)
-530 piston & rings
-Machine shop work (bore and replate cylinder, balance crank, press on new balancer)
-timing chain, springs, retainers, gasket kit, tensioner
-rod and main bearings
-tires
-hoses
-Chain, sprockets, chain guide
-rear brake lever
-Shifter
-radiators
-new bolts and powdercoating some of the ugly stuff
-Exhaust system

Thinking about a single Arrow slip on or a dual Arrow system from the special catalog. Want this to be a quiet ride in the trails, for i remember my 450 was quite obnoxious. Just don't want to be "that guy" calling attention to himself.

Would like to do the rebuild myself, mainly to save money. All depends on how business goes.

If anyone has some nice 510 or SMR parts for sale, let me know :-)

 

[268fords]

Good luck keeping it quiet. The two cans will just cost a bunch of money. There is plenty of high output lights out there that will be worth looking into vs. Buying the stock light.

 

[cbreakin]

Looks like an awesome project! As stated previously you'd be doing yourself a huge favor by installing the SMR counter-balancer assembly while the engine is apart. I'd also look into the thicker factory head gasket to lower compression some. At least out here in CA that small mod goes a long way to combat our less than great pump gas. It also appears that the previous owner swapped out the front Brembo caliper for something else? The dual exhaust is not that quiet unless you leave the cats in place, also they will require you to find an SMR subframe to mount correctly. I can't comment on the arrow duals, however I can't see them being more quiet than derestricted stock duals which are pretty loud. I think you'd be better off with with an FMF Q type pipe or the stock arrow with the optional "db" killer in place. I wouldn't call the FMF quiet per se, but it's note is much less offensive then that of either the stock single arrow or derestricted SMR duals.

 

[ghte]

Forks and swing arm do not show much in the way of drop damage. It appears more a case of ride and garage and skip wash and maintenance bit. Hopefully at that mileage it will still be in reasonable nick internally. Good luck and please keep us abreast of progress with photos too!!

 

[Planepower]

You showed a picture of your triumph, and I thought you were going to convert it to a 'super single' race bike. Now that would be awesome!

 

[antirich]

You showed a picture of your triumph, and I thought you were going to convert it to a 'super single' race bike. Now that would be awesome!

Believe me, I've thought about it!

Considering that my 450SMR grenaded in 2300 track miles, I'm not sure the Husky motor is idea for road track bike. Probably would do better with a KTM 690; also a lot more road track parts for the KTM as well. Would love to build something that'll go up against the SVs.

Almost picked up a very nice 550SVX for that purpose, but I've had so-so experience with the Aprilia 550 in the past. BeOn in Spain makes a nice all in one conversion kit for most of these bikes.

 

[antirich]

Forks and swing arm do not show much in the way of drop damage. It appears more a case of ride and garage and skip wash and maintenance bit. Hopefully at that mileage it will still be in reasonable nick internally. Good luck and please keep us abreast of progress with photos too!!

Yea, I'm going to be pulling the motor today to look inside. I have a feeling at least the head's been off, so we'll see.

Can't believe that the parts for a single are so expensive. Especially since they don't last as long, vs. a typical I-4. Hopefully I can at least pull off the labor.

 

[antirich]

Looks like an awesome project! As stated previously you'd be doing yourself a huge favor by installing the SMR counter-balancer assembly while the engine is apart. I'd also look into the thicker factory head gasket to lower compression some. At least out here in CA that small mod goes a long way to combat our less than great pump gas. It also appears that the previous owner swapped out the front Brembo caliper for something else? The dual exhaust is not that quiet unless you leave the cats in place, also they will require you to find an SMR subframe to mount correctly. I can't comment on the arrow duals, however I can't see them being more quiet than derestricted stock duals which are pretty loud. I think you'd be better off with with an FMF Q type pipe or the stock arrow with the optional "db" killer in place. I wouldn't call the FMF quiet per se, but it's note is much less offensive then that of either the stock single arrow or derestricted SMR duals.

Didn't know FMF made a 'quiet' muffler. Something like this?

http://www.ebay.com/itm/NEW-FMF-Q4-...d=100005&prg=1088&rk=2&rkt=5&sd=271340448162&


or this Arrow slip on that someone redone:

http://www.ebay.com/itm/27134044816...em=&sspagename=ADME:X:RTQ:MOTORS:1123&vxp=mtr

 

[cbreakin]

Didn't know FMF made a 'quiet' muffler. Something like this?

http://www.ebay.com/itm/NEW-FMF-Q4-Q-4-QUIET-EXHAUST-MUFFLER-09-HUSQVARNA-TXC250-TE510-TXC-250-TE-510/280832754269?rt=nc&_trksid=p2047675.m1851&_trkparms=aid=222002&algo=SIC.FIT&ao=1&asc=261&meid=3813916482899585254&pid=100005&prg=1088&rk=2&rkt=5&sd=271340448162&


or this Arrow slip on that someone redone:

http://www.ebay.com/itm/27134044816...em=&sspagename=ADME:X:RTQ:MOTORS:1123&vxp=mtr

That FMF pipe is exactly what I was speaking of. That Arrow slip-on will make more power but will be loud, as it's just a perforated core straight through design, where the FMF is baffled. With the 510 trading 3hp peak horsepower to be less loud isn't a big deal, that bike has power to spare in all off road situations!

 

[antirich]

OK, SOME UPDATES/TEARDOWN, and a few surprises.

First off, found lots of nice little bits in the oil screen. I remember this was quite common on my 450, but still not something you want to see. NOthing too large, clearly tiny filings, but not something you want in the rings. Lots of orange sealant, not too worried about that:

On the bench, and ready for the teardown:

Cams seem to have normal wear for 4300 miles. Not sure how bad this is, but the plating is clearly worn. No broken bits that I can see:

Hears the REAL surprise, piston is clearly not original, and in almost perfect shape :-). Same goes for the cylinders. Clearly, someone has replaced it not too long ago. The black stuff you see came off with a rag and some brake clean; hardly any of it baked on the piston.

Hears the piston after I cleaned it off. None of this black gunk was stuck on. Take not of the pits in the middle; obviously something metal got in there, but couldn't find any broken bits in the valvetrain:

Bottom of head looks normal. Some very minor marks on the valves. Gasket was the factory (?) 1.2mm. This stuff was a baked on a bit, so i left it alone for now.

Ducati starter? Not sure what to make of this.

Clutch also looks to be pretty new, as well as the plates.

So at this point, I'm not sure if its worth breaking the cases open. Looks like someone did a bit of motor work, but all seems to be somewhat stock.

I clearly see what the head gasket went: the outer head nuts came off with my fingers! Obviously they were never checked. Other motor bolts were pretty loose as well, but not the four head/stud nuts.

I'm going to try to contact the company that did the shock, maybe they know something. The kid I bought it off didn't know much, just that it's fast and loud. No records or paperwork.Said was was filling it up with gas one day, and saw white smoke coming out the pipe and the motor. Shut it down and had the bike picked up.

Oh, and the muffler was total crap; almost came off in three pieces. Felt like all of the packing was gone. Header bolts where loose, and household springs were used on the mid pipes.

 

[ghte]

Ducati starte,r normal, MV Augusta clutch, normal all left overs from the common parts bin from the Cagiva ownership days, I would open her up and have a look, something not quite true here for a bike of 4300 kms.

 

[antirich]

Ducati starte,r normal, MV Augusta clutch, normal all left overs from the common parts bin from the Cagiva ownership days, I would open her up and have a look, something not quite true here for a bike of 4300 kms.

Not true in what way? Do you see other damage?

 

[ghte]

Just the external condition, the gunk in the engine sieves and piece of mind really, just an old riders feel rather than anything specific or obvious. Good luck with which ever way you go forward. Love the 510's, had an 05 a ways back and they are a real weapon and very robust.

 

[antirich]

OK, rethinking the 530 route, and thinking it may be best to invest in a better/stronger bottom end.

I had my SMR450 crank balanced and a Knife rod installed by Fallicon, and really liked the difference. Thinking about sending this crank out to them as well.

Has anyone done any major crank work to their 510 before? Wondering if it should be lightened a bit to increase revs, or if Falicon's balancing would negate the need for the SMR balancer on the 510 crank.

Halls has a Pro-X rod for the 510 that's a bit cheaper than the factory one; which saves $100 or so. Falicon doesn't make a Knife rod for the 510 :-(

Any preference to crank/rod bearings, or are the factory ones the only choice?

I think for the top end, i'll jet get the valves redone, new rings and the RR water pump for now. Piston and bore looks very nice.

 

[Xriderdown]

OK, rethinking the 530 route, and thinking it may be best to invest in a better/stronger bottom end.

I had my SMR450 crank balanced and a Knife rod installed by Fallicon, and really liked the difference. Thinking about sending this crank out to them as well.

Has anyone done any major crank work to their 510 before? Wondering if it should be lightened a bit to increase revs, or if Falicon's balancing would negate the need for the SMR balancer on the 510 crank.

Halls has a Pro-X rod for the 510 that's a bit cheaper than the factory one; which saves $100 or so. Falicon doesn't make a Knife rod for the 510 :-(

Any preference to crank/rod bearings, or are the factory ones the only choice?

I think for the top end, i'll jet get the valves redone, new rings and the RR water pump for now. Piston and bore looks very nice.

I rebuilt mine with all OEM parts. Not because I'm one of those OE types. I just don't have enough experience under my belt with the aftermarket motorcycle engine parts. And the money saved wasn't really that much in my case. $1k is what I spent on parts alone for a stock bottom end and top end rebuild less the valves......ouch! The valves were inspected and reseated. My engine overheated due to the water pump coming apart. I would recommend replacing the water pump with the factory high volume pump while you're in there. I've got just over 1k miles on the motor and she's still running like a "striped ass ape".


Here's some action shots of the teardown in progress.

View: http://vimeo.com/57824913

 

[Theo]

Ducati starter? Not sure what to make of this.

IMO that's not a starter taken from a Ducati bike: it's a part (likely to be OEM) made by the brand "Ducati Energia": http://www.ducatienergia.com/eng/prodotto.php?id=41, which is related to Ducati Motor: http://www.ducatienergia.com/eng/azienda.php. In fact, the writing states "DUCATI e".

 

[antirich]

So what's everyone's opinion on the photos of the existing piston? Does it look aftermarket?

Short of some nicks on the done, i think it's OK to reuse. Would like to just replace the rings if they're cheap enough and take a hone to the cylinder wall.

Does anyone deck the heads on these, or will that raise the compression to a dangerous level? I thinking a bare minimum will at least assure a better gasket seal.

Goal is to secure the bottom end as best as possible; for replacing the top end is fairly easy if I wanted to go the 530 route later on.

 

[ghte]

Asisde from the Ducati "E"; look at your clutch It has MV Augusta-all part of the old Cagiva days.