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November 2nd, 2014, 06:53 PM   #1
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From: Portland, Oregon

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I Ride: 2007 FE650
2007 FE650 Build

Hey guys, I recently aquired a 2007 FE650 with 49 hours on the clock. I thought I'd start a build thread to document my progress and hopefully get some advise along the way.

The teardown:


As it sits right now:


Thanks from bushmechanic
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November 2nd, 2014, 07:16 PM   #2
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Here are the first parts I picked up for it. A guy was selling them used on Ebay. I think they came off a 530EXC or something like that. He claimed they were too stiff for him. And don't worry, I'll strip off that ugly orange before it goes on the Berg.

.52kg/mm fork springs and Racetech P30 progressive shock spring:
Thanks from bushmechanic, OldMan and Bjorn
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November 3rd, 2014, 12:33 AM   #3
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subscribedddddd ...
What's the plan for the bike? A refresh or any changes?
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November 3rd, 2014, 08:47 AM   #4
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I Ride: 2007 FE650
Originally Posted by tourist View Post
subscribedddddd ...
What's the plan for the bike? A refresh or any changes?
The primary goal is to disassemble everything, clean and grease, and reassemble. It's in great shape, but it is a little dirty.

There are also some modifications I'd like to make involving suspension and ergonomics.
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December 20th, 2014, 10:28 PM   #5
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Finally ordered a bunch of parts tonight! Rings, gaskets and seals for the engine and front rim and tires for the chassis. The heavy fork springs are installed with new oil, but I still have to get the shock spring powder coated yellow.

This also happened. Nothing too crazy, just smoothing the transitions and casting flaws:
Thanks from bushmechanic and 520pilot
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December 21st, 2014, 08:10 AM   #6
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Are you getting the double valve springs?
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December 21st, 2014, 10:55 AM   #7
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Originally Posted by Bluto View Post
Are you getting the double valve springs?
I wasn't planning on it. Is there a problem with the stock springs?
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December 21st, 2014, 07:45 PM   #8
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I Ride: 2008 700FK, 2002 628FST
some people have them break at around 200 -250 hrs, others get 30 000 km+ out of them.

many to choose from, Kibblewhite offer the best set, they often go for $160 new on ebay

specs here

All About Valve Springs! (with nice pics)

might as well do the cam follower bearings at the same time KTM PN# 590 36 061 090 they about $21 from munn
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Last edited by bushmechanic; December 21st, 2014 at 08:06 PM.
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December 22nd, 2014, 07:15 PM   #9
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I Ride: 2007 FE650
I might wait until 100 hours to do more work to it. This 45 hour teardown isn't really a rebuild, more of an assessment of what I've got. I'm trying not to spend too much on it all at once

The bore has some scars in it. It must have pulled in a few grains of sand at some point. I touched it lightly with a hone to make sure there were no high spots:


Also, the piston went out today to Line2Line Inc for their skirt coating:
Line2Line - Slick CC
It's supposed to reduce skirt clearance to "0" and for $35 it seemed like a good deal.

I believe once I tighten the skirt clearance with the coating and install new rings, it will be happy for another 50 hours. Then I can look into a new piston, liner, valvesprings etc.

For the record, here's the list of parts on order:

Engine:
Gaskets
Water pump seal
Shift shaft seal
Kickstart seal
Output shaft seal
(all the oil seals were seeping)
Timing chain link
Piston rings
Valve cover vent tube (it was cracked)
Oil filter
Spark plug (DCPR8EIX)

Tires:
Full Bore M37 110/100-18 and 80/100-21
(I can't believe how expensive Dunlops have become. These are cheap and have good reviews.)

Front wheel:
Excel ICS408
(look closely at the picture in the first post and notice the large dent in the stock wheel)

Bar risers:
Enduro Engineering #23-002

Grips:
Renthal half waffle medium compound

I am also considering buying a jet kit from Taffy. It seems to flame out easily at low speeds.

Pardon the color of the bike, but this is an illustration of its favorite time to flame out:


Will a jet kit help? It already has a quick adjust fuel screw and a Boyesen accel pump cover. Maybe some fine adjustments are all that is needed.
Thanks from bushmechanic

Last edited by JGBerg; December 22nd, 2014 at 07:18 PM.
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December 22nd, 2014, 07:30 PM   #10
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there are a few different jet kits

and if you like to fiddle the honda NKBT is a pretty good needle

I made one a bit like an nkbv

Bushmechanic Mongrel 628 Trailbike

it helped close the transient lean spot going from a steady 1/8th to WOT where the accel pump wasn't operative.

the honda needles are about $20

Bushmechanic Mongrel 628 Trailbike
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