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April 1st, 2016, 07:15 PM   #1
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I Ride: 04 FE650
FE650 04 Carb mid body o-ring

Hi guys my name is Ray I'm from Australia and I recently took ownership of an 04 FE650 with just 51 hours and 2600kms on it.
It did however have a flat spot down low in the revs. After inspecting the carb I found that the accelerator pump nozzle was blocked, after many hours of trying I could not unblock it.
To fix it I purchased the Athena Dual Spray Venturi Kit, as apparently you cannot buy the original single spray nozzle new.
The kit came with 2 mid body o-rings and neither are the correct fit, one is close but where the corner of the o-ring is at one end there should be a small 45 degree section, but it has a 90 degree corner instead.
I stretched the oringinal o-ring when removing it, so it no longer fits into the groove.
I am thinking about buying a FCR Mid Body Rebuild Kit off ebay which comes with new internal hex bolts and 2 different o-rings.

Has anyone used one of these kits before and did one of the o-rings fit?
Alse does anyone know where I can purchase the correct o-ring if the ebay kit does not work?

Thanks, Ray

Last edited by ray2448; April 1st, 2016 at 07:19 PM. Reason: forgot one piece of information
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April 5th, 2016, 12:56 AM   #2
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try sudco usa, thumper racing usa or ktm talk user "DJH"
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April 5th, 2016, 11:32 PM   #3
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Thanks mate
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April 8th, 2016, 11:42 PM   #4
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Alright so we all know for future reference the o-ring that come with either the athena or jd jetting dual spray kit and the one that come with the mid body rebuild kits advise that they do not fit any ktm 2005 or earlier nor any yamaha from 2002 or earlier.
Now I would assume the berg uses the same variant of the fcr as ktm back around that era.
According to sudco usa Keihin themselves do not produce this o-ring as there stance on the issue is that this part of the carb is non servicable.
I am going to attempt to repair my original stretched o-ring by slicing out a small section and using rubber glue to stitch it back together.
If this does not work I will have no choice but to by an fcr 41mm off another bike and fit my jets, needle, slide, float bowl and all other transferable parts into it.
If I do this I will make sure the fcr I get is a variant that these aftermarket o-rings fit so I know that I can get the parts if I need them.
Also these variants of the fcr on ktms and older bergs do not run a leak jet in the float bowl, it is cast over and blanked out.
So if you have a ktm pre 2005 or a berg around the same era DO NOT remove the mid body o-ring as there is no way to replace it if you stretch it.
Thanks, Ray
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April 9th, 2016, 06:05 PM   #5
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Carburettor rebuild kit
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April 10th, 2016, 10:21 PM   #6
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Thanks mate but those o-rings look exactly the same as the ones that came with the dual spray kit.
Neither are correct for my carb, my o-ring looks like a combination of those two, it is like the top one only with 45 degree corners on the right side rather than 90 degrees, the bottom one has the 45 degree corners but the circular part on the left side is wrong.
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April 15th, 2016, 06:10 AM   #7
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I have shortened one of the non fitting new o-rings with a razorblade and superglued it back together at the right length and superglued it into its groove. So far all is good and the bike is running fine. We will see how it holds up over the next few rides.
Thanks from tourist
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May 22nd, 2016, 02:49 AM   #8
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This is look like an option;
Mid Body Gasket JDKH17 Cut to Fit FCR Carb with Removeable Flange photo - James Dean photos at pbase.com
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May 23rd, 2016, 12:08 AM   #9
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we run the same carb that KTM fitted for just two years. it is the FCD MX carb and the years that KTM used it were 2004-2005. before this it was what we call the Mk1 carb and yamaha used this in 1998 and 1999 on the YZ and 1998-2000 on the WR. they also then went to the MX carb. If your kit fits neither of these then all it leaves is the ingly shyte 'production carb' that Homda always fitted to the CRF and so did KTM from 2006 and then some others as well. I don't have exact dates for other stuff but I can say that Husaberg only fitted the FCD MX carb in the years 2004-2008.

Taffy
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