• Hi everyone,

    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

    When he passed, I worked with his kids to gather the necessary credentials to keep this site running. Since then (and for however long they worked with Coffee), Woodschick and Dirtdame have been maintaining the site and covering the costs. Without their hard work and financial support, CafeHusky would have been lost.

    Over the past couple of weeks, I’ve been working to migrate the site to a free cloud compute instance so that Woodschick and Dirtdame no longer have to fund it. At the same time, I’ve updated the site to a current version of XenForo (the discussion software it runs on). The previous version was outdated and no longer supported.

    Unfortunately, the new software version doesn’t support importing the old site’s styles, so for now, you’ll see the XenForo default style. This may change over time.

    Coffee didn’t document the work he did on the site, so I’ve been digging through the old setup to understand how everything was running. There may still be things I’ve missed. One known issue is that email functionality is not yet working on the new site, but I hope to resolve this over time.

    Thanks for your patience and support!

Removing/refitting 510 cylinder liner

Krudd

Krudd

Husqvarna
AA Class
I have a 1989 510 magnesium cylinder that is knackered by oxidation, but the liner is like new.
And then I have an aluminium cylinder with a knackered liner.

I'm wanting to swap liners to make one good cylinder, but I am afraid I may damage the aluminium liner or Nikasil coating when pressing out.

Anyone here with experience of removing/refitting cylinder liner in a liquid cooled Husqvarna four stroke?
I have removed other liners by heating in an oven but they were air cooled alu cylinders with steel liners. Never done it with alu liners in alu cylinders..
 
Update: At least I got the liner out of the magnesium cylinder.
I cut a slit in the water jacket with a hacksaw and Dremel. The liner pushed out easy then.
There was lots of oxidation residue stuck inside.. Wouldn't have gotten much cooling with that on there!
DSC_0689.jpg
 
Here's the magnesium cylinder with the slit. Trimmed the inside of it a bit too.
I used this as a "receiver" for the liner that was to be pressed out of the alu cylinder.

510cyl slit.jpg

Stacked them like this in the press. Here I've already pressed out the liner.
I first used a metal plate, then the good liner I took out of the magnesium cylinder, to press out the bad liner from the alu cylinder.
Heated the outside on the alu cyl first.
I was hesitant to use the good liner to press as I didn't want to "mushroom" the end of it, but it was ok. Didn't need too much pressure to push out.

510cyl 2.jpg


Using the old cylinder as receiver also prevented the upper surface on the alu cylinder from being damaged as it got support all around.

Fitting the liner will hopefully be easy as I remembered we have a freezer at work that goes to minus 70 degrees Celsius.

510cyl 3.jpg
 
Using my home freezer at minus 20 Celsius for the liner and heating the cylinder water jacket to 150 Celsius in the oven was good enough to refit.

1b.jpg

So that one is sorted. Now I need to figure out how to get all the thick oxide build up out of the head's water jacket..
I'm thinking to try and loosen it with some mild acidic solution and then bootle brushes on power drill.

2b.jpg

Then the valves will need cleaning and grinding.. This is one of the exhaust valves.
This bike has less than 1000 kms on the odo but probably not stored in a heated place at times, and apparently with the exhaust valves open.

3b.jpg
 
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