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March 9th, 2019, 08:11 PM   #1
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I Ride: 2001 FC470e, 2016 KX250F w/ 290 kit, 2005 CRF80
Lightbulb FC470e starter woes

I have decided to reinstall my starter on my 01 FC470e. I used all the updated parts that was suggested and I'm still having a little trouble?
I purchased a used Yamaha R6 starter mounted everything went together pretty easy but she won't start on the button? To me the R6 starter seems to turn just as slow as my old stock starter? I'm thinking maybe I bought a worn-out starter off eBay? I took it apart and didn't see any issues? Is there a noticeable difference of the R6 starter cranking and the stock cranking old starter?
I'm thinking my jetting might be a tad rich on the pilot also, it's really hard to say because she kicks over first kick!
So what do you guys think?
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March 9th, 2019, 08:19 PM   #2
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What updated parts did you use ?
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March 10th, 2019, 12:32 AM   #3
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Have you tried jump starting off another battery? Try a car battery. Your probably kicking it over faster than the starter motor.
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March 10th, 2019, 06:26 PM   #4
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FC 470e starter woes

[QUOTE=husabutt;189070]What updated parts did you use ?[/QUOTE)

Now that I look at it it wasn't that many parts! I bought a used 99 compatible starter motor, a 04+ motor mount and a YTZ7S 6 amp 130 cca battery. I checked and had to shim my starter gear. Most of my parts are pretty new, when I first mounted my starter in 02 it didn't work for crap so I took it off right away. No need to have the extra weight when it doesn't work!
I built all new battery cables and double grounded the system.

Do you see anything I missed? I'm thinking of a new starter?
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March 10th, 2019, 06:30 PM   #5
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FC470e starter woes

Originally Posted by canolman View Post
Have you tried jump starting off another battery? Try a car battery. Your probably kicking it over faster than the starter motor.
I jumped the starter off the bike with my ATV 12 amp battery, the starter still seemed slow to me? I'm thinking I purchased a bad starter?
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March 11th, 2019, 02:35 PM   #6
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The #1 issue why 2001 and early 2002 models will not e-start is that they had too much internal drag in the engine. In late 2002 the transmission was modified with a different tooth profile to lessen the drag. The following parts were changed: Counter Balancer, Balance Drive Shaft, Drive Gears on the Balancer Drive Shaft and the outer clutch basket. So if you are serious about getting your 01 – early 02 to e-start replace the above mentioned tranny parts with late 02-03 items. Probably 04-08 parts would work as well but I am not sure.

If you have a late 02 or 03 then a more powerful starter would be a good idea as the Autodecompression Device does not bleed off enough compression during e-starting. Using the 04-08 Cam and Autodecompression device Takes care of this issue. In 05 the 650’s received a larger starter motor than the 450’s.

2001 and early 2002 models had a solid starter “Reduction Gear” aka in late 02 as the “Torque Limiter”. This would cause damage to the starter motor and clutch basket if a backfire occurred during e-starting. These Reduction Gears were replaced with Torque Limiters under warranty. The gears should slip if 9-15 Nm of torque is applied. Make sure you have the Torque Limiter installed before attempting to e-start. In your post you stated that you shimmed the “Starter Gear” so it seems that you are probably good here as that is the way to fix a Torque Limiter.

Husaberg used to sell a thicker head gasket to help lower the compression. The 470’s seem to have a ton of compression. On my 2001 470 I have installed the Torque Limiter (under warranty), an 05 650 Starter Motor and bracket, thick Head Gasket and YTZ7S Battery. It will turn the motor over a few times before it runs the battery down or the sprag (or Torque Limiter) will slip. So lowering the compression a smidge and using a larger starter helped a tiny bit. A Husaberg factory mechanic told someone on this site to use 2 12V batteries connected in series to send 24 volts to the starter. This was before the engineers had addressed the starting problem.

A few have been able to get an 01, early 02 to e-start without changing the transmission gears by using: YTZ7S battery or equivalent, Larger starter, 04-08 Cam and Autodecompression Device and Dual Valves Springs (softer springs = less engine drag). I think that the battery would still run down fairly quickly even if it will spin fast enough to start.

The SEM ignition is yet another problem of sorts. I think that the engine needs to spin about 300 RPM before it will create a spark. So a very slow cranking motor will not cut it.

A 2001 or early 2002 will probably never e-start as good as a 04-08 model. If you don’t change the internal gears it will always be iffy. Sometimes though taking imperfection and trying to make it perfect or at least as good as possible can be a fun challenge.

Last edited by husabutt; March 11th, 2019 at 03:07 PM.
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March 11th, 2019, 07:32 PM   #7
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Originally Posted by husabutt View Post
The #1 issue why 2001 and early 2002 models will not e-start is that they had too much internal drag in the engine. In late 2002 the transmission was modified with a different tooth profile to lessen the drag. The following parts were changed: Counter Balancer, Balance Drive Shaft, Drive Gears on the Balancer Drive Shaft and the outer clutch basket. So if you are serious about getting your 01 – early 02 to e-start replace the above mentioned tranny parts with late 02-03 items. Probably 04-08 parts would work as well but I am not sure.

If you have a late 02 or 03 then a more powerful starter would be a good idea as the Autodecompression Device does not bleed off enough compression during e-starting. Using the 04-08 Cam and Autodecompression device Takes care of this issue. In 05 the 650’s received a larger starter motor than the 450’s.

2001 and early 2002 models had a solid starter “Reduction Gear” aka in late 02 as the “Torque Limiter”. This would cause damage to the starter motor and clutch basket if a backfire occurred during e-starting. These Reduction Gears were replaced with Torque Limiters under warranty. The gears should slip if 9-15 Nm of torque is applied. Make sure you have the Torque Limiter installed before attempting to e-start. In your post you stated that you shimmed the “Starter Gear” so it seems that you are probably good here as that is the way to fix a Torque Limiter.

Husaberg used to sell a thicker head gasket to help lower the compression. The 470’s seem to have a ton of compression. On my 2001 470 I have installed the Torque Limiter (under warranty), an 05 650 Starter Motor and bracket, thick Head Gasket and YTZ7S Battery. It will turn the motor over a few times before it runs the battery down or the sprag (or Torque Limiter) will slip. So lowering the compression a smidge and using a larger starter helped a tiny bit. A Husaberg factory mechanic told someone on this site to use 2 12V batteries connected in series to send 24 volts to the starter. This was before the engineers had addressed the starting problem.

A few have been able to get an 01, early 02 to e-start without changing the transmission gears by using: YTZ7S battery or equivalent, Larger starter, 04-08 Cam and Autodecompression Device and Dual Valves Springs (softer springs = less engine drag). I think that the battery would still run down fairly quickly even if it will spin fast enough to start.

The SEM ignition is yet another problem of sorts. I think that the engine needs to spin about 300 RPM before it will create a spark. So a very slow cranking motor will not cut it.

A 2001 or early 2002 will probably never e-start as good as a 04-08 model. If you don’t change the internal gears it will always be iffy. Sometimes though taking imperfection and trying to make it perfect or at least as good as possible can be a fun challenge.
Thanks for all the info! I forgot to mention I did all the above head work i.e. 04 cam, chain wheel and decompression. I also updated my valves spring to dual spring set up. I will look for a thicker head gasket but I'm not sure I really want to go through all the gear changes? She starts right up w/ the kick starter. After reading the Wiki page on the starter mods I thought it would be nice to have a starter on her? Now it seems it will be more trouble than it's worth? I'm not giving up, I'm just going to put a limit on how far I'm willing to go.
Thanks again for all the info.
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