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Discussion Starter #1
Ok well it's time to rebuild my 06 510. It has a tad over 12,000 miles and never let me down. I figured I would give her a complete rebuild including a 530 kit. I took all the pics to use as a reference for assembly but maybe it will help someone here.


Do not pull on the oil line it is held in by the cam holders


Remove the cam holders. Do not mix them up but they are numbered 1-4


Set them aside for now.


Remove the 4 head nuts AND washers. You will need to turn the engine upside down to get the washers out.



Remove the cam chain tensioner
 

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Discussion Starter #3 (Edited)
Remove flywheel nut


Remove the flywheel


Attach all parts together in order



Remove the waterpump this will allow you to pull the gear up slide off the cam chain. Let it drop into the flywheel area.


Remove the two bolts on the left side of the head


Remove the two 13mm nuts on the bottom of the head studs. One fwd and one aft.
 

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Discussion Starter #4 (Edited)
Remove the head
Remove the cylinder bolt


Remove all case bolts marking them in order


Attach case splitter. This is a husqvarna made splitter. Sure it was 180.00 but made light work of splitting the case.
 

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Discussion Starter #5 (Edited)
Cases split!


VERY IMPORTANT!! This shim must go back in. Pay close attention to it.


This shows the counter ballancer alignment.


Next remove the clutch cover and clutch and basket paying attention to the fat washer on the back


Remove the cover marking the order of the bolts


Cover removed
 

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Discussion Starter #6 (Edited)
Pay attention to the orings there are two. One for the oil filter and one sitting in the oil pump


The nut is reverse threads. Right to loosen


Remove this little gear taking notice of the thin washer. Once the gear assembly from the crank is removed reinstall the gear


Remove the gear and spacers and attach together in order


Using a mallet lightly tap the crank out. Your done!!
 

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Discussion Starter #7
Here is my 12k cylinder and piston. Piston had no blowby and the walls were near perfect still. I have no doubt it could gave gone another 8-10k. Except the lower rod bearings are a known weak point

 

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Piston looks about perfect as far as wash maybe a little lean. I can't believe how nice the cylinder looks:thumbup:

Good Job

Is you 530 kit in yet?
 

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Discussion Starter #9
No 530 yet. I'm sending the head off for inspection, the crank to have the counterballancer gear pulled. And installed on my new RR crank. Since they don't have a counterballancer.
And since I'm waiting I'm powdercoating the cases that matte black like my covers.

I'm also rebuilding a 04 450. The lower rod bearing went on that motor blowing the cylinder. So I'm giving my buddy my 510 cylinder and crank. But he is putting a new rod in my old crank.
 

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  • Don't forget to put the crank spacer back on the STATOR side!
  • Also wise to inspect the oil pump and the transmission shift drum. They can wear out over time. Especially check the oil pump, it's a vital component to your engine.
  • When pulling out the transmission, start by removing the shift forks and their shafts. you can then CAREFULLY pull out the two trans shaft assemblies together, same time. Be careful not to lose any gears as some of the parts are loose and can slide off. Inspect transmission for unusual wear and damage. If it's good to reuse as-is, then wrap up the two shafts together as one assembly. Use plastic shrink wrap and they'll be assembled, protected and nothing will slide off.
 

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Discussion Starter #14
Thanks Brian!!

This is the crank spacer. When you split the case it may be stuck to the bearing or may be sitting on the crank by the ballancer like in the second pic. That's a 04 450 that blew. I'm rebuilding that one too.

 

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This is awesome! Anyone know if there are any big differences between how this 510 comes apart and how the 610 does?
 
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