449/511 Important Urgent Flywheel Inspection

I used a smear of Loctite 515 only around the oil gallery & reused the cleaned gasket.
No oil weeps as yet.

Ouch....! So it isn't a Taiwanese thing then?

The allen head bolts are very shallow, I'm not sure you'd get a hole drilled through without weakening them further....
I didn't measure the clearance while I was in there but maybe a 6mm Nordlock washer would fit underneath the head?!?



As for the alert, it was Helmut who posted his damage up & I remembered seeing another damged stator earlier.
Their bad luck is our saviour. Sorry you guys took the pain for the rest of us!

This is what a community like this does though, the sharing of info helps all of us.

These engines were assembled in Berlin. I have seen this issue a few times. Use spray solvent to clean threads, compressed air and green loctite.

By Kymco??

Correct, Green or Red loctite will be fine (290 or 271). Both have similar break-away strengths.

I wouldn't select a Loctite product just by the color only. I believe 290 "green" is for assemblies already put together and is a wicking compound. The color Green Loctite alone is available in
Numbers, 609,603,640,638 and 290. Each has a different application.

Use green 290 loctite. Yes, it's low viscosity. It won't come loose in the hot oil and it's made for small fasteners. Red may be difficult to remove for repair without heat and that's not a part you want to heat too hot..

Engines manufactured in Tiawan, assembled in Berlin. Great engine, rebuilt over a hundred.

Threre you go, cheers=)
Another case of global manufacturing that makes no sense.
I imagine it was a case of having 'assembled in Germany' bragging rights

It was cheaper through the use of even crappier pot metal.

We have had the local arm of GM,Holden, here forever building our home built cars.
The main one being the Commodore which will cease production soon.

The V6 engine option uses a block made in Mexico & assembled here.
In fact all the alloytech V6 enignes for GM are currently built this way & sent to the other markets.
I still fail to understand how it can be viable to do this, shipping patrs to one country, building a product from it & shipping again somewhere else.

For cleaning the threads, Tinken mentioned using spray solvent. Would carb cleaner be good? Brake cleaner? What's a good spray solvent? And I don't recall seeing the torque specs for the bolts.

Brake & parts cleaner would be fine.(There are specialist Loctite cleaners but they are crazy expensive)
Best not to get too much of it in the engine cavity though.
Post number 7 from Helmut, for torque, 25Nm

I wish I had seen this posting. My stator is shredded one of those little bolts came loose and just destroyed it. $400 dollars plus shipping to replace it. Husky is becoming not my favorite brand very quickly

Sad to hear mate but they really are a great bike.
Yes, like most European cars/bikes I've had anything to do with there's things to watch out for but over-all they are a great machine.

I was reminded by Scott's post to go work on this this weekend. Couldn't find the Green 290 loctite anywhere. So I picked up some red, but in doing some googling, turns out we aren't the only ones with this problem. DRZs do too: http://www.thumpertalk.com/topic/548456-stator-and-starter-clutch-loctite-fix/
The first post in the above TT thread recommends medium loctite for the flywheel bolts.

Unfortunately I did not get to work on this because my buddy and I ended up welding modifications for our newly acquired harbor freight tire changer with motorcycle attachment all day.

Don't leave it too long Cosmo
It doesn't take long at all.

Guys, I'm working on this right now. I pulled out the 8 bolts. When I lift up on the cover it comes about a quarter inch off and I start to feel some serious resistance. Is it attached to a spring, or is the alternator magnet pulling back on the cover?

No problem. Pull off gently. Take care of the gasket and two sleeves.

Thanks. It came out no problem. I found my bolts to be perfectly tight. Pulled them anyway and they were already coated with a thread lock. The coating was mostly white with some green.