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January 5th, 2013, 11:37 PM   #1
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FE400 00model - need help troubleshooting electrical problem

Hello all

I'm new here, and I arrive with a problem.
I have a FE 400, year 2000 model, but build in 1999. It's the third time I have electrical problems. The cdi was repaired once and the stator twice... this is starting to make me a bit sad with the bike. Looks like she doesn't like water much... how do you guys in England cope with this? Anyway, I had it fixed the first two times in Portugal, where the workmanship is cheap and I know my way around, but now I moved to France, and feel the need to identify the problem myself. So please, give me a hand !
The Problem:The bike has no spark with kickstarter; the battery is completely dead
The story:Third time I have the electrical system going dead on the bike. First 2 times it was while running, after some water crossing. This time was when satrting the bike after months of neglet (I was working abroad) and the thing was dead. Was fine before.
What I've done so far:
I just checked for spark with the kickstarter - nothing
Next steps:
- connect a battery from my '89 super tenere and see what happens (somebody told me that a dead battery can be the cause for a dead electrical circuit - I'm not sure about this, but no harm in trying...)
- Get a multimeter and start checking... and here some help would be great!

Thanks all
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January 6th, 2013, 02:05 AM   #2
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Re: FE400 00model - need help troubleshooting electrical pro

hi there

your in luck, i am a sem rewinder and i also have came across this problem, but i have a cure.
i repair stators for £120 with free return postage to anywere in the world and 12 months warranty, also i supply a stator cover gasket free of charge to help look after the new repaired unit.
iv had many husabergs that use SEM and all of them suffered with water in the stator cover, so i used my common sense and made a gasket ( i thought that they had no gaskets because husabergs are a bit rare and no body knows were to buy them from?? ) but after researching over and over i found that husaberg never made a stator cover gasket. i have heard something about the cover having a o-ring to seal but i have never seen 1.
since i have been using a gasket on the cover i never suffer with a wet stator.
i have 1 rewind in portugal with user ( ZAGA ) he was having this problem of water getting in the stator cover, he has been running 1 of my rewinds with 1 of my gaskets and he now has a dry stator all the time ( im sure when he reads this he will pop in and tell you a little more ).

i have never heard of a dead battery stopping an older husaberg from sparking as the sparking side and charging side are completely seperate .
the only way to tell if your stator is dead is to test it with a multimeter you want to see
between wires red/black 3000 ohm +/- 10%
between wires green/black 168 ohm +/- 10%

cheers kris
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January 6th, 2013, 02:47 AM   #3
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Re: FE400 00model - need help troubleshooting electrical pro

Yes they have an o-ring sealing the cover and it is definitely watertight. Water is still getting in there. The o-ring is a pain, it is easier to omit the o-ring and maybe put some thick grease on the mating surfaces as a sealant. The cable feedthrough might be the biggest culprit in letting in water.

It is a good habit to undo the three cover screws after you hosed off the bike after use, pull out the cover a little bit and then put either the allen wrench in between to keep the gap open, or a small wooden wedge or whatever at hand. That way the ignition is drained and well ventilated and dried until the next ride and your ignition will last many times longer.

Alternatively, you can drill a drain hole at the lowest point of the flywheel compartment so anything running in will also run out, but it will also let lots of water and mud in to churn during water crossings so maybe not the best solution.

The SEM ignition does not rely on battery power and kickstarting does give higher revs than cranking so if the ignition works it should work with the kickstarter. I get the feeling it seems to take a wake up kick or two if the bike have not been ridden for many months though.. The spark from SEM is a bit thin and sometimes hard to see in broad daylight. The OEM sparkplug cap is one thing that might fail, leaving you without spark, replace with one with or without a resistor, these spark plugs already have a resistor in them so the extra resistance of the OEM cap is not necessary.

Regarding stators, multimeter stator readings off the scale indicates a bad stator but "good" readings does not guarantee a good stator, it can still be bad.
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January 6th, 2013, 06:39 AM   #4
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Re: FE400 00model - need help troubleshooting electrical pro

Thank you guys. Checking the resistence on the stator tomorrow first thing. Hope it's only the stator dead...
Last time the mechanic sealed the thing with silicone. Looked pretty water tight. I'll see tomorrow if I see moist inside.
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January 7th, 2013, 01:45 AM   #5
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Re: FE400 00model - need help troubleshooting electrical pro

you need to seal the top of the wires as they enter the wire tube, the tube to the bung and the bung to the cover.

I as you'll know also supply SEM stators repaired.

the flat battery has nothing to do with a spark BUT I think you're right in that the spark is weaker even though technically it shouldn't be!

regards

Taffy
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January 7th, 2013, 02:07 AM   #6
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Re: FE400 00model - need help troubleshooting electrical pro

Hi guys
Just checked:
between red and black I have 1.2 kOhm
between green and black I have 163 Ohm
Not sure if I'm going to repair the stator because it will be the third time! Maybe I buy a new one. I see in ebay a electrex replacement model for the ST5410L at £190, and a german shop selling one of unknown brand for 160.
Are the electrex any good?
Also, is there something else I should check?
Thanks
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January 7th, 2013, 02:57 AM   #7
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Re: FE400 00model - need help troubleshooting electrical pro

they keep going wrong because you keep making the wrong choices - clearly!

buying electrex is a bad move. read my ad for my SEM and I tell it straight how it is. there's a link in my signature.

even a new SEM will fail quite quickly as the factory closed in 2008 and all KTM stock is now very old. a reconditioned unit is the right way to go but an electrex is the wrong way.....

regards

Taffy
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January 7th, 2013, 03:55 AM   #8
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Re: FE400 00model - need help troubleshooting electrical pro

Ok, just checked for feedback on the internet and looks like electrex isn't good, and they use cheasy tactics to promote their stuff.
So I'm going to have it repaired. Isn't there anything else I should check on the bike?
I asked for prices here in France since I guess shipping to England will increase costs too much. But if prices are simillar, I'll send it to Kris because he replied first here.
Thanks all
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January 7th, 2013, 04:52 AM   #9
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Re: FE400 00model - need help troubleshooting electrical pro

Hi

Were did you had your rewind in Portugal, is it still in Alentejo ?

Cheers
ZAGA
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January 7th, 2013, 09:33 AM   #10
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Re: FE400 00model - need help troubleshooting electrical pro

OlŠ Zaga

No it's in France. First repair was done in Leiria, and I sent de cdi to a guy in Porto, second time I gave the bike to a mechanic near Coimbra (ECMotos) and he sent it somewhere, not sure where.
Tens 3 husabergs? Tens de me aconselhar uma bateria boa e barata. Vou mandar o stator ao inglÍs... parece-te boa ideia?
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