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May 8th, 2019, 09:35 AM   #1
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I Ride: 99 FC600, 95 FC501, 94 FE501, 02 FE650
650 Starter Delete Plug

2002 FE650

The wiring is a mess, and it is missing the starter relay. I have it starting 1-3 kicks with the kickstarter and want to remove all the electric start items.

I bought the OEM aluminum plug from a FC470 to fill the hole, after the starter is removed. I expected a groove to be in the case, for the o-ring around the plug to fit into, to hold the plug in place - but there is nothing.

Does the plug really just sit in the hole?

Is it wise to use some silicone sealer to glue it in?
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May 8th, 2019, 12:18 PM   #2
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I Ride: "2000" FE600, 1996 FC660, 1994 FE501 (in pieces), 2001 FE 501 (in fewer pieces), 2015 Beta Xtrainer
I just did this to a 501 a few months ago and I wondered the same thing. I recently looked at a parts manual and the picture in the manual indicated that the plug is supposed to have a step in the outside diameter that keeps the plug from falling into the engine. Also, the picture showed a screw and washer on the inside of the engine, presumably to keep the plug from falling out. In any case, the plug I received had none of these features. I drilled and tapped a hole in the middle of the plug and then drilled and tapped holes in the engine case on either side of the starter hole. I think that the holes were 4mm. Then I built a retainer out of thin aluminum and drilled 3 holes in the retainer that match the locations of the 2 holes in the engine case and the 1 hole in the plug. With the retainer screwed in place, the plug can neither fall into the case, nor fall out. I'll take a picture when I get a chance.

In retrospect, I imagine that the plug is meant to be bonded in place with some sort of adhesive since it was supposed to be used in the MX models and the ability to remove the plug was not of high importance.
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May 9th, 2019, 06:19 AM   #3
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I Ride: 99 FC600, 95 FC501, 94 FE501, 02 FE650
Thanks for the info. Yes, based on the OEM parts schematics, I expected the plug to be held in place with a retainer bolt - perhaps the FC cases are slightly different...

I am thinking of using either locktite sleeve retainer or a silicone gasket maker as an adhesive to hold it in place. Just concerned about what effect vibration could have.

Curious to hear from others' experiences though.
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May 9th, 2019, 07:43 AM   #4
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I Ride: "2000" FE600, 1996 FC660, 1994 FE501 (in pieces), 2001 FE 501 (in fewer pieces), 2015 Beta Xtrainer
VOR, I work for ICON Aircraft where we build the A5 LSA. We use the Loctite sleeve retainer in many locations and my experience with it has it being somewhat brittle once fully cured. My fear is that engine vibration might lead to failure of the adhesive. If it were me, I'd use a 2-part epoxy to secure it.
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May 9th, 2019, 08:16 AM   #5
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I Ride: '08 HUSKY te610
the one on my 02 650 just pushed in and stayed there
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