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Fuel Fuel Delivery

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  • 1 Post By Taffy
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December 4th, 2017, 06:57 PM   #1
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I Ride: 2005 Husaberg FE450e, 2010 Harley XL883c, 2010 Aprillia 750 Shiver GT, 2001 Honda CBR1100xx
Fuel leak at carby - 2005 Fe450e

Hi Guys

A little story 1st then my problem.

The 'berg has been virtually unridden this year, so when a mate said "Lets go for a ride this Sunday" I said "Great!". It had spent probably 4 months under a cover in my garage. My mate was pretty excited too and I found out later he had spent all of his Saturday prepping his Kato 300 2T.

When I pulled the bike out I noticed most of the knobs ripped off the front tyre. Off to the shop for a new one. Whilst there they told me this could have been the original tyre as my FE is a 2004 built/2005 mdl and the tyre was made in 2004!!!

Anyhoo, after re-fitting the front wheel I went to start the beast and was surprised when there was enough juice in the battery to turn her over. It would fire a little, maybe run for a couple of seconds then stop. I thought fuel problem - old fuel, blockage, whatever (?). Now, whilst trying to track this down I ran into a bigger issue....

There was fuel dripping off the carb onto the gearbox, and if I left it long enough it was forming a puddle under the bike (gulp!). The fuel line looked very old so hoping this was the cause off I went and bought some new stuff. No good - still leaking.

It now looks like the brass fitting (where the fuel enters the carb) pivots within the alloy carb body and it is here that the fuel is leaking. Should this brass fitting pivot/move at all? Has anyone else seen this and know of a fix? Do I need to get a new carb/carb body? If so, what's best place/way to get one?

PS: I have never seen any evidence of the carb leaking before. The 'berg has always started and run easily. I will be pulling the carb and checking/cleaning the jets, whacking in a new spark plug, ensuring the air filter is spotless etc. It will also have an oil and filter change before next ride. In any case I need to fix the leak as it is very concerning/dangerous.

Thanks in advance for your help!
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December 4th, 2017, 08:12 PM   #2
Joined: Mar 2017
From: Vancouver, BC

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I Ride: 2008 FE 550
What carb? Mine is the FCR 41. I Had this same leaking issue.

Or at least I thought I did. Ended up I pinched the float gasket on the prior carb service. I tried to remove the fuel inlet fitting's o-rings and they literally disentgrated. Super dry and old.

So I ordered the all-gaskets FCR kit. It also comes with the o-rings for the fitting in question. Yes, it has a bit of play laterally, and of course rotationally, but should have zero radial play.

So when I reassembled it all the leak was gone. Which was the actual contributor? Hard to tell because the corner where the gasket was pinched was directly over the fitting. All I could see was the fitting was wet and leaking.

From the state they were both in, it was likely both. So my advice is get the seal kit and fix all the o-rings. At least the easy to access ones. It's a pain to take the carb out any more often than you have to - eliminate all possible failure points in one go.


Last edited by canadius; December 4th, 2017 at 08:15 PM.
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December 5th, 2017, 12:12 AM   #3
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I Ride: 2005 Husaberg FE450e, 2010 Harley XL883c, 2010 Aprillia 750 Shiver GT, 2001 Honda CBR1100xx
Thanks Canadius.

Ill order the seal kit and replace all that I can when I take out the carb. I bet the same disintegration of the rubber o-ring will be the culprit.

It might take a couple of weeks but ill let u know once done....

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December 5th, 2017, 12:45 AM   #4
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I Ride: Husaberg FE501e 2003
Hi Grassy

you have two o rings on that braass tube and they have gone rock hard and worn a little too. that is why you're leaking. if you have trouble getting them I have them here in the UK. just undo the phillips screw around the back and have it out.


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December 7th, 2017, 07:58 PM   #5
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I Ride: 2005 Husaberg FE450e, 2010 Harley XL883c, 2010 Aprillia 750 Shiver GT, 2001 Honda CBR1100xx
Thanks for the help Taffy.

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December 9th, 2017, 06:28 AM   #6
Joined: Jan 2011
From: N. Cal

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I Ride: fe450
I had the same problem, both O rings were shot.
Be sure to take the float bowl off and inspect the carb for crud. I found little black hard chunks of old O ring inside.
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December 11th, 2017, 02:47 PM   #7
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I Ride: X2 08 Fe 650 & 04 Fs 650 berg, 012 700 rapter, 013 superjet, 98 wave blaster
Had same issues
Went to bearing place for mind, couple spares cause my brass was very loose I add extra o ring... Fix it
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  Husaberg Forum > Mechanical and Technical > Fuel

2005, carby, fe450e, fuel, leak

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