Pistons

Prices & Stock - (Last stock update 1st June 09)

102mm Piston – Big-bore your OEM Liner

This is the latest aftermarket piston from JBS Racing for the Husaberg. The idea was to make the larger cubic capacity engines available to people on a more limited budget and to repatriate old worn OEM liners as they are now very to get. The piston is designed to drop straight in any “650” model Husaberg simply by boring out the OEM from 100mm to 102mm. This gives 654cc on the 80mm OEM crank and 670cc on the OEM 82mm crank.

For full technical details see our Piston Library section in our Tuning Shop. If you thinking of using this piston in an application other than the 650 Husaberg please contact us for advise ben.ballard@jbsracing.co.uk

Price - £210

Current Stock – 6

105mm Piston

The original piston from the JBS Racing “700” kit.

Price - £240

Current Stock - 13

JBS Racing use the most advanced computer aided design techniques from the aerospace industry to ensure that our performance parts are lighter and stronger than the competition. Click the links below to see some key components undergoing FEA stress simulation testing.

Piston 105mm - Finite Element Analysis    (10.2mb)
Crank OEM - Finite Element Analysis    (2.35mb)
Connecting Rod OEM - Finite Element Analysis    (1.51mb)
Connecting Ron JBS - Finite Element Analysis    (1.41mb)

Requires a .avi player to view. Download here - Real Player

108mm Piston

The original piston from the JBS Racing “735” kit. Can be fitted to the Husaberg if the cases are bored to accept a special liner. Has also been successfully fitted to a KTM LC4.

Price - £290

Current Stock – 5

100mm Piston

Pistons to OEM specification for any model Husaberg. Please state the model at time of ordering.

Price - £180

Current Stock – None

For further information on the extensive range of pistons that JBS Racing can supply see our Tuning Shop - Piston Library & Billet Piston Info

Gaskets

Husaberg Aftermarket Gasket Set 2000-2008

Complete universal gasket set includes –

Clutch Cover
Water Pump Cover for 2000-2003 Pumps
Water Pump Cover for 2004-2008 Pumps
2 x Rocker Cover
Chain Tensioner
Ignition Cover for 2004-2008 Engines

This is the gasket set that JBS Racing supply to many Husaberg dealers in the UK including Dave Clarke Racing and can be found on ebay. It is used by British Sidecarcross Champion Stuart Brown in British and World Championship competition. This “universal” set is how we buy it from our manufacturer and we do not split our sets.

Price - £22

(Discounts available for order of 10+ and to British and World Championship Sidecarcross teams email ben.ballard@jbsracing.co.uk)

Current Stock – 60

Husaberg Aftermarket Head Gaskets

Head gaskets with the unique JBS Racing reinforced outer profile developed for the “700” kit now available in all bores. JBS Racing supply these gaskets to many UK Husaberg dealers including Dave Clarke Racing and they are used by British Sidecarcross Champion Stuart Brown for British and World competition.

Prices & Stock

Bore 98mm - £12     Stock - 11
Bore 100mm - £18    Stock – 23
Bore 102mm - £25   Stock – 4
Bore 105mm - £30   Stock – 13
Bore 108mm - £30   Stock – 8

(Discounts available for order of 10+ and to British and World Championship Sidecarcross teams email ben.ballard@jbsracing.co.uk )

We also stock soft Aluminium, Copper and MLS (Multi-Layer Steel) gaskets for the Husaberg for extreme engine requirements. Aluminium and Copper are suited to engines with a very long stroke and MLS are used for turbo and nitrous applications all need special modifications and fitting. Chances are if you are interested in these you have my email address already!

Prices & Stock

Aluminium 100mm - £20     Stock – 0
Aluminium 105mm - £20     Stock – 56
Aluminum 108mm - £20      Stock- 0

Copper 105mm - £40 Stock – 12

MLS 105mm - £65 Stock – 2
MLS 108mm - £75 Stock – 2

Kits & Tuning Parts

JBS Racing Husaberg “700” Kit

This the original JBS Racing “700” kit as used by Supermoto racers in UK, Sweden, Poland & France – Desert and Flat-track racers in the USA, and Sidecarcross Champions in National and World Championships.

Kit includes –

JBS Racing 105mm Piston – Light weight forged piston
JBS Racing 105mm Liner – Ultra-strong Duramoly Iron
JBS Racing 105mm Head Gasket – Custom strengthen profile
Stud conversion kit for head – M10 Course thread for cases, M10 extra-fine for nuts to hold head, special retaining washers.

With OEM 80mm crank kit gives 693cc and with OEM 82mm crank kit gives 710cc. We only recommend running with the 80mm stroke crank that which has a 35mm pin though we do have several customers that are running with the 82mm stroke and 32mm pin. The kit does not require any machining to fit and fitting can be done by any competent mechanic with experience of Husaberg engines.

Price - £515 Stock – 8

Spares

Piston - £240            Stock – 13
Liner - £292      Stock – 2
Gasket - £30     Stock – 13
Stud Kit - £86          Stock – 48

JBS Racing Husaberg “735” Kit

This is the latest big-bore kit from JBS Racing and include a massive 108mm piston. To fit this piston it is necessary to set the cases up and bore the liner registers to a larger diameter. This kit can only be run with the 80mm stroke crank and JBS uprated rod and JBS Racing main bearing modification and oil cooling and ignition cooling! Engine appears the same externally.

Kit Includes –

JBS Racing 108mm Piston
JBS Racing 108mm Liner
JBS Racing 108mm Head Gasket
Stud conversion kit for head

It does not include machining of the cases to accept the kit.

Price – POA Stock – 4

Main Bearing Conversion

The main bearings on the Husaberg are a major weak spot. JBS Racing were the first aftermarket manufacturer to try and tackle this problem, especially in Sidecarcross. After trying every combination of ball or roller bearing in existence all of which failed we have the solution. The solution is to bore out the cases by a small amount and fit super-alloy steel liners, into which spherical-roller bearings made to JBS Racing specifications with a mounting flange machined as an integral part of the outer-race are clamped by retaining nuts. This along with special seals provides the only truly workable bearing upgrade for the Husaberg no other tuning shop can offer a solution that even comes close. Forget “special” ball bearings, wider rollers, bronze cages etc we were the first to try them all and none of them work. Our current solution does and is run in British and World championship races by British #1 Stuart Brown.

This system can be run with or with-out the counter-balancer.

Here are some technical ratings from the bearing manufacturer (SKF) –

OEM Husaberg Ball-bearings 2000-03 – Axial – 0kN Radial – 19kN
OEM Husaberg Roller-bearings 2004-08 – Axial – 6kN Radial – 44kN
“Special” optimised fill ball-bearings – Axial – 0kN – Radial – 23kN

JBS Racing spec' spherical-rollers – Axial – 19kN Radial – 64kN

Prices & Stock

JBS Specification Bearings - £59 / each                Stock – 24
Steel bearing liners, nuts and screws - £91 / each      Stock – 4
Crank seals for JBS conversion
- £18 / pair (1 x drive & 1 x ignition)                   Stock - 3
Machining cases and fitting - £252

NB - This conversion will soon be rendered obsolete by JBS Racings new cases. See the "Coming Soon" section below.

JBS Racing Replaceable-Lobe Camshaft

A camshaft like no other, both the exhaust and inlet lobes bolt onto a hardened and ground high-tensile steel carrier. They are retained by a keyway and clamped in place by an M16x1.00mm nut (same size as the crank). Each lobe is individually adjustable so the overlap and cam timing can be closely controlled. New lobes can be supplied for far less than the cost of an OEM camshaft and lobes can be miss-matched so that different profiles of inlet and exhaust can be tried together for optimum results for your unique application of the Husaberg engine. This cam fits all models of Husaberg and we can modify it to fit KTM’s.

Prices & Stock

Replaceable Lobe Camshaft + A set of Lobes - £263 Stock – 24
Spare Lobes from our stock lift and duration series
(please enquire for spec’s) - £98 / Pair
Custom lift and duration Lobes to your profile - £168 / Pair

Heavy Duty Cam-Chain

Heavy duty cam-chain from Regina. Stronger than OEM, supplied linkless must be installed with a chain splitter. This is much better than a split link for racing purposes.

Price - £38 Stock – 40

OEM Husaberg 80mm “Bell” Crank

New OEM crankshaft. Can be fitted to older models of Husaberg we strongly recommend this over the older OEM crank. This crank has a 35mm diameter big-end pin and an 80mm stroke the older crank has a 32mm diameter big-end pin and a 82mm stroke. Stiffness increase as the fourth power of the shaft diameter so the added 3mm makes a huge difference. We do not recommend that you run any JBS Racing power increasing modifications on the older crank.

Additionally JBS Racing can press your crank for you to install a new conning rod. We can press old or new style Husaberg cranks or indeed any engine crank. We will true the crank in all planes to a higher specification than the OEM requires. We can also perform balance factor alteration with our extensive stock of Tungsten.

Prices & Stock

OEM “Bell” Crank - £450 Stock – 0
Crank pressing - £100
Crank Welding - £50

Titanium Pins

Made from 21 Grade Titanium as used on the spars of the JSF Joint Strike Fighter and coated with Diamond-Like Carbon by Brunel university. These pins weight 39 gms the OEM pin weighs 80 gms, they are stronger than the OEM pin. The only down-side is the cost.

Price - £189 Stock – 5

Ignition Cooler Cover

Modification to the OEM ignition cover of the SEM or Kokusan type ignitions to provide an inlet and outlet21mm hose connection. This helps to circulate air around the ignition cooling it as well as removing some heat from the crank case all of whish helps with reliability.

Prices & Stock

Ignition Cooler Cover with exchange cover from customer - £60
Ignition Cooler Cover no exchange cover - £110

Oil Cooler Kit

Oil cooler kit based on the finned tube oil cooler as used by British Sidecar Champion Stuart Brown in British and World Championship racing. The finned tube cooler is much tougher than a standard radiator cooler, you can literally stand in it, none of the problems of cracking that are found with Mocal and similar coolers when used in Sidecar. Kit includes -

JBS Racing die-cast oil cooler adaptor
JBS Racing Finned Tube Cooler
Hoses

Prices & Stock

Solo Kit as above with a 200mm long finned tube cooler, mounts on down tube
- £295 Stock – 0

Sidecar Kit as above as above with 1 x 450mm long finned tube cooler
- £395 Stock – 3

Sidecar Dual Kit for larger Cubic Capacity engines as above with additional external screw-on high capacity filter replaces OEM filter and 2 x 450mm finned tube coolers - £505 Stock – 1

Here is the kit installed in British Champion Stuart Browns Sidecar.

Range of colours available, not always all in stock. Also custom lengths up to 800mm long x 75mm diameter.

When we experienced problems with the main bearings we contacted our bearing supplier SKF and they made the following response - SKF Running the JBS Racing oil cooler is one of the main reasons that British Sidecar Champion Stuart Brown's engines have been so reliable in the 2009 season.

Complete Engines

Complete Engines

Husaberg 650 model engines removed from bikes. Supply is very limited evey time we get an engine in we sell it immediately and have a waiting list. Please register your interest with me ben.ballard@jbsracing.co.uk

Approximate prices –

New 2008 engine complete with carb, electrics & e-start - £4500
2006 Engine as above - £3000
2004 Engine (first of new type ignition, circular crank) - £2500
2003 Engine as above (old style ignition) - £1800

Coming Soon

This section is to alert you to products that JBS Racing are currently developing and give an idea of when they will be available. With all small run specialist products the price and indeed whether a manufacturer will make them at all or not is determined largely by numbers. So if you are interested in any of these products please register your interest with us and we will try to arrange our ordering of parts so that we can cater for everyone that wants to make use of the service.

JBS Racing 650 Cases

New main cases for the Husaberg 650 internals. These cases are much stronger than stock being both thinker in key areas and cast from a stronger Aluminium alloy containing high levels of Copper and Magnesium. This alloy is much harder to cast than the alloy used by the OEM (EN AC-Si7 Mg 0,3) but has a tensile strength that is 1.5 time higher.

These cases have been made simply because it is almost impossible to get your hands on new replacement cases from Husaberg now and the cost is very high. As we were making cases anyway it was sensible to make them stronger so that larger capacity engines can be built into them.

The OEM Husaberg cases are the lightest of any 4-stroke MX engine we have ever seen, they are even lighter than KTM 250 sx-f cases. Which sounds good but they break easily and there's no points for DNF.

Features include –

Thickened walls at all keys areas of stress
Larger main bearings
Larger water jacket
Extra mounting points directly below the crank and at the head

Approximate Price & Delivery

Price - c£800 Complete with uprated bearings Due – July 2009

Stronger 650 Conrod

We have been developing a connecting rod for the 650 bell crank that is stronger than the OEM rod for use with JBS Racing big-bore pistons. This rod has proved economical to have made and will also be a very good rod for use in standard engines. In order to increase the strength and stiffness of the rod to make it reliable for GP use in the 700 engines the rod has to be wider than the OEM rod. This means that the crank has to be machined and re-balanced to take it but once this is done swapping the rod is as easy as it is with the OEM rod. Also the OEM rod can be put back on to a modified crank with no additional work.

Approximate Price & Delivery

Connecting Rod - £180 Due – June 2009
Crank Modification - £112

Pre-2000 Husaberg Complete Gasket Sets

Gaskets from the same aftermarket manufacturer as the JBS Racing gaskets for the modern engine will be available soon. The set will include every gasket on the pre-2000 engine including the base gasket for the cylinder. Head gaskets will also be available for all bores that Husaberg made.

Approximate Price & Delivery

Complete gaskets set – c£28
Head gaskets – c£20

Uprated Oil pump with 40% more flow

The oil pump on the Husaberg is an after thought the original engines didn't even have them. The pump is too small to cope with the demands placed upon a racing engine. JBS Racing are currently trialling an oil pump that increases the flow by 40%. It is a direct bolt in upgrade no machining needed. It is of particular use with oil coolers.

Approximate Price - £100 Due - June 09

Uprated Water Pump

A new water pump rotor and water pump cover developed by JBS Racing using CFD analysis has optimised true hydrofoil vanes and generates almost twice the flow that the OEM rotor / cover does. Race engines can often suffer fast temperature gradients in the cylinder, for example full throttle up a hill. Engines can cope with this if they have either high thermal inertia or fast thermal response. For example the Zabel 2-stroke has a very thick barrel and crank cases giving a lot of mass of aluminium to heat up and high thermal inertia preventing hot spots. Formula 1 engines have very thin barrels and low mass cylinders but very high coolant flow rates and vary large radiators giving low thermal inertia but a fast thermal response which again prevents hot spotting. The Husaberg has neither it has a very thin cylinder and tiny water jacket (less volume than a can of coke inc the head) giving low thermal inertia and a poor coolant flow due to an inefficient pump rotor and small coolant passages. So the Husaberg is prone to seizing due to heat spikes say at the top of a hill climb on a track that the engine can cope with easily if it get the heat out. The new JBS Racing cases are designed to have high thermal inertia and the new JBS Racing water pump dramatically increases thermal response.

Also coming soon -

Twin-spark head conversion and non-OEM rotor, stator & CDI
Billet stroker crank-shaft based on the 750 crank with improvements
4-Speed non-OEM gearbox
Clutch from Barnett to fit the Husaberg

More CC’s

Additionally JBS Racing can offer engine building to GP specifications. We add locking tab washers to all the nuts, drill additional oil ways and make many small tweaks that make the difference between a record number of wins in the hands of the British Champion and everyone else! We have two dedicated "white bays" for engine building that are scrupulously clean with multi-axis engine building stand and specialist tools in each, no one in the country has better Husaberg engine building facilities or any that even look like competing.

Again please register your interest in any of these products with us at ben.ballard@jbsracing.co.uk demand affects how many we plan to make and numbers strongly affect the price to you.