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September 5th, 2011, 05:53 AM   #1
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e-starting problems

Hi!
I'm new on this forum, so at first I would like to say HELLO!!!!

I have a problem with my FE501 Berg (2001).
I have just mounted e-starter with brand new battery.
Engine starts "from first kick" (cold or warm), but I can't start it from electric starter.
After small investigation I know that there is no spark on spark plug when I try to use e-starter.

What I have measured:
-I have around 50-60VAC between red-black wire from stator (using kickstarter or e-starter)
-3,5-3,7VAC between green-blac wire using e-starter and 5,5-5,7VAC using kickstarter (I know that those measurements are depend on strenght of my muscle and e-starter/battery condition but I also know it can be compare to other machines)
-resistance green-black 215ohm
-resistance red-black 1,64kohm

I have borrowed CDI unit (ICU 10) from my brothers 501 berg ............and my berg starts very nice.
There was nice visible spark with my brothers CDI unit.

In my berg CDI unit has only 3 cables from generator (red/green/black) and two for motor bike wiring (orange-kill,black-ground) so I don't have possibility to conect Hi/Lo switch it looks like factory made........

Does someone has similar situation/problem?
On 18.09 I will take my Berg to Romania but at first I want my E-STARTER!!!!!

With Best regards Damian (Berg_501)
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September 5th, 2011, 08:22 AM   #2
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Re: e-starting problems

what year and model 501 is your brother's bike?
hopefully you left out the fact that your cdi has a white output wire or you are dealing with a non estart cdi. i believe the white wire boosts the cdi voltage as the estart is engaged. is your bike originally an estart model or did you add all the parts and electrics to make it an estart?
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September 5th, 2011, 08:55 AM   #3
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Re: e-starting problems

for electric start you need a CDI with

red
green
black

also

black again
white
grey
orange
if you don't have the white and grey you have kickstart only CDI as Ned says.

also, your stator is three wire (black, green and red) so this is only for Motocross. all it will do is run your ignition. No Lights and no charging of the battery.

sounds like you have a 2000 FC501 and not a 2001 FE501. you can give me the 3-3-2 numbers off the end of the CDI unit and I will tell you which engine this CDI was for?

you'll also find that the stator has a very small fllywheel as well so even if you change the CDI and the stator you also have to change the flywheel!

remove the stator from inside the cover and check the positioning for the correct ignition timing. underneath it you should find a small aluminium ring that your stator is sitting on. it must come free and then it is a spacer. if all you have is the cover underneath? then you must have this alloy ring!!!

regards

Taffy
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September 5th, 2011, 10:50 PM   #4
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Re: e-starting problems

Hi!
I have checked in spare parts catalogue and there isn't mentioned any "distance" between stator and alternator cover......but for me it isn't any problem to make it I have a lathe, Taffy do You have dimmension of that ring(thickness)?

My motorbike is 100% FE model, I suspect that someone could change the CDI unit.

Regards Damian
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September 5th, 2011, 11:01 PM   #5
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Re: e-starting problems

HI!
on my CDI unit:
ICU10/DE56
855 190 01
25021602

CDI unit which I borrowed from my brother was only ICU10 with out "/DE56"

Regards Damian
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September 6th, 2011, 01:22 AM   #6
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Re: e-starting problems

Originally Posted by Berg_501
HI!
on my CDI unit:
ICU10/DE56
855 190 01
25021602

CDI unit which I borrowed from my brother was only ICU10 with out "/DE56"

Regards Damian
they didn't do a 250 216 02 !!!!!!!
they did a 250 226 02 which is from a 2000 FC600
they did a 250 226 01 which is from a 2000 FC501

your readings are wrong as well.

the red to black should be 2800 and it's this one that goes wrong.

the green to black is 160 and is always OK.

regards

Taffy
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September 6th, 2011, 02:08 AM   #7
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Re: e-starting problems

Hi!
Taffy please see photo from my picasa:
https://picasaweb.google.com/1015717759 ... Lipca2010#


"the red to black should be 2800 and it's this one that goes wrong.
Taffy"
gentlemans so I think that problem is solved........ my reading is too low.
But I'm very curious why it is working properly with other CDI?

What do You think it would be ok! if I connect CCFL inverter to black-red to suply AC voltage to CDI unit for starting? (I have seen that idea on this forum)

My engine is starting very well with out any problems (I can start the engine by left foot siting on the bike).

I think in few days my stator will end

Regards Damian
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September 6th, 2011, 02:23 AM   #8
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Re: e-starting problems

I'm not an electrician so i don't know. Sorry!

try a PM to OYK. he's not here very often but he has forgotten more than I'll ever know.

regards

Taffy
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September 6th, 2011, 02:50 AM   #9
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Re: e-starting problems

Hi!
idea with DC/AC inverter i have found in below link:
http://www.husaberg.org/forum/viewtopic ... =schematic

Regards Damian
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September 6th, 2011, 08:31 AM   #10
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Re: e-starting problems

prolly ought to work if tied into red as per other thread. good recycling tip if you happen to have a CCFL laying around.
can't say how long the cdi will take it before failing, tho.
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