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December 20th, 2016, 01:00 PM   #1
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Flashover FS650 2002

Hi!

I am struggling starting my Husaberg FS650 2002 model. The stator was broken, sent it to taffy for a rewind, messured and all within the specs. Still got no spark after the rewinded stator, so i started troublshooting thru the wiring.

When i just connect all the nessecery wires, red-black-green from the stator to the coil and black to earth from the coil. Got sparks now and then, sometimes there is and sometimes there is no spark at all. But i noticed that i could feel a weak shock in my hand when holding the sparkplug to ground.

I took off the black earth wire from the coil and the bike got spark every time! Talked to my dad and he told me it could be a flashover from the coil to earth.

Is the coil broken then? Have not had time to try start the engine with the earth wire removed from the coil, but will do tomorrow.

Appreciate all answers
Andreas
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December 20th, 2016, 05:38 PM   #2
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To rule out a bad ground/earth put a wire from coil to the motor. Bypassing frame
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December 21st, 2016, 08:13 AM   #3
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you sure you didn't confuse grey wire for black?
Attached Thumbnails
Flashover FS650 2002-cdi-1-.jpg  
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December 21st, 2016, 12:08 PM   #4
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Yes, did clean the wires very well to see the colors.

The problem now is that i need to kick the engine over real fast to get a spark. The engine needs to turn over waay faster than other engines i have been into. And i do not get a spark at every turnover. It won't spark if i connect the wires to the low/high ignition curve button, so maybe there is a short circut somewhere.

But my starter motor have no chance turning the engine so fast over that it will spark, even though i have a Yamaha R1 starter mounted and a car battery...

Getting tired of this bike now...



Is is much work to fit a auto decomp on this bike, 2002 FS650? Will new and better valve springs help the starting?
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December 21st, 2016, 12:43 PM   #5
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i had an'02 fx650 that started quite well on the estart and was a 1-2 kick bike. but to get it to do that was a LOT of work. it required the yam starter ( i used the 600), and the steel cam sprocket (which required the cam be machined), and the later profile (dutch clog) autodecomp. the original autodecomp was a poor design that quickly wore out. i also had a keihin fcr carb which helped.
are you using the proper starting technic? a 650 does not like to start unless you start the kick at barely after tdc compression.
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December 23rd, 2016, 12:49 PM   #6
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Thank you for answers

Have kicked it over a thousand times, just past tdc. I have tried different adjustment on the kickstarter decompression cable slack, from almost no decomp to more and more decompression. Used startgas to just hopefully hear it ignite, but with no luck.

Done the 1/6 turn on the valves, using the right TDC. Have adjusted the ignition just past the right mark on the flywheel. I have a rewinded SEM stator and have just the necessery wires connected to the ignition coil. Have a spark while kicking it over very fast, no spark using the electric starter with R1 starter motor. Think it has a good spark, but it is my first husaberg so i don't have any reference on how it should be. But i am now wondering if it could be the coil that is the problem.

I will try to jumpstart the bike as soon as the snow melt from the hill outside my garage.

And also another question, will the auto decomp device fit my bike, or do i need to buy the 08 model camshaft? And can someone give me an explanation of modifying the cam shoulder, maybe with a picture of where it should be machined?

Taffmeisters - Husaberg, KTM, Husqvarna, Gas Gas, dirt bikes - servicing, tuning, rebuilds, parts
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December 24th, 2016, 08:25 AM   #7
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the '02 will have an aluminum cam sprocket with the old style autodecomp which is prob knackered.

the good autodecomp is shorter than the old because the steel sprocket has a recessed lip. so to get the newer decomp, about .060? needs to be removed from the cam to get rid of the gap, and the steel sprocket needs to be used.


OR...just find an '04 up cam with decomp and sprocket. (prob cheaper)
Attached Thumbnails
Flashover FS650 2002-berg-650-decomp-1-.jpg   Flashover FS650 2002-berg650-new-autodecomp-1-.jpg  

Last edited by ned37; December 24th, 2016 at 08:27 AM. Reason: clarify
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December 24th, 2016, 09:53 AM   #8
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the first half of the 2002's had alloy Ned but the second half had steel whist all the way through, the cams had the broad shoulder.

so this fella could be saving on his sprocket?

if it is on the road I would go for the later cam anyway. the old cam will be marked '53' on the end.

regards

Taffy
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December 26th, 2016, 08:37 AM   #9
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Okey! Thanks for nice answers and pictures

I have the opportunity to machine the cam down at work, so i have just ordered a new cam sprocket and also the auto decomp device.

And since i already will be working with the head, i ordered new valve stem seals, headgasket, modified cam chain tensioner blade, new cam chain and new rocker inspection gaskets. I think i will take the head off to clean and if necessary grind the valves and valves seat.

The bike was bought with unknown service history, so i will try to check all wear parts and clean everything down.
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December 26th, 2016, 09:47 AM   #10
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sounds like you're on your way.
don't forget a new spring for the autodecomp.
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