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July 23rd, 2018, 12:44 PM   #1
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2009 FE 450 won't start

I bought this bike from a friend. It ran when I bought it then after changing the oil it ran for about a minute, shut off and has not started since.

So far I have:
  • Swapped the entire fuel system from a running 2010 FE450
    • tank
    • fuel pump/filter
    • fuel rail
    • injector
  • Fresh oil change
  • Clean air filter
  • New battery @ +12V
  • New plug gapped to spec
  • Checked valve clearance
  • Increased/Decreased idle
  • Set TPS to .64
  • Swapped ECU
  • Swapped plug
  • Checked and cleaned coil wire
  • Jumped diag pins to read codes - none present
  • Checked fuses
  • Tried starting fluid

I pulled the plug and it looks brand new and a little wet.
This makes me think the fuel system was/is not the issue.

Any guidance would be greatly appreciated

Here is an album of some of my testing
https://imgur.com/a/BF9XaFc


Last edited by bayside08; July 23rd, 2018 at 01:56 PM.
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July 24th, 2018, 09:31 AM   #2
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I would immediately suspect the fuel system when it comes to no start/stalling issues with these bikes. I would also go through the wiring harness to check for damaged wires/oxidized connector pins.

Last edited by NoClassic; July 24th, 2018 at 09:34 AM.
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July 25th, 2018, 06:48 AM   #3
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Originally Posted by NoClassic View Post
I would immediately suspect the fuel system when it comes to no start/stalling issues with these bikes. I would also go through the wiring harness to check for damaged wires/oxidized connector pins.
Thanks for the response NoClassic. I suspected the fuel system as well, however I have swapped over a new tank, injector, and everything in between. When I look down the TB I can see fuel is spraying fine as well as puling the spark plug shows it is wet and getting fuel.

I also tried starting fluid but it would not start, which leads me to believe it is not fuel related.

The reason I posted in the electrical section is because it seems I've eliminated the fuel system, but maybe I'm missing something. I sanded down the ground connections and verified i have good connections.

Are there any connections/sensors you would recommend to check that I have missed? I will be measuring the resistance of the pulse generator this evening.
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July 25th, 2018, 09:40 AM   #4
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I would try to find someone in your area with one of the XC1 diagnostic tools.
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July 26th, 2018, 06:00 AM   #5
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Thanks! I just reached out to a friend of mine and he said their shop has an XC1. I had never heard of that tool before. I really wish they were readily available to the public
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July 26th, 2018, 08:54 AM   #6
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I know they were at one time available for purchase and may still be. I think the list price is near 3K though.
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July 26th, 2018, 09:05 AM   #7
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Well I think you can buy them, the issue is getting the software
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July 26th, 2018, 10:18 AM   #8
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That makes sense. I was however able to find this with a quick search.

https://www.ebay.com/itm/OEM-KTM-Dia...item4b367177fd

I was always curious if the free TuneECU software was able to connect to the Husaberg control system but could not find any solid info. I actually have one of the diagnostic USB cables but have yet to attempt to connect to the ECU.

Last edited by NoClassic; July 26th, 2018 at 10:23 AM.
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July 26th, 2018, 07:50 PM   #9
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What would cause my battery to sound like its dying after I crank it a couple times?

Torque limiter?

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July 27th, 2018, 01:29 AM   #10
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The battery is weak and not maintaining high enough terminal voltage during cranking, the ECU senses the low voltage and then stops firing the plug.

Replace the battery.
Thanks from jon andersson
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