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September 2nd, 2009, 08:29 AM   #1
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FE 400 issues

Yesterday i bought myself a FE 400 03 model. Outside it's great condition and everything works good but i have trouble with restarting the engine. When it's cold i pull the choke on, and fire it first or second kick with kickstarter every time.
But when i try to restart the warm engine with electric starter it just don't starts.

I noticed that if I stall the bike and try to start the bike immediately with el. starter then it starts great but if i let it sit 5 seconds than i can't start it, also if i let it sit more than 10 seconds i can't kickstart the engine without the choke, it fires once and dies every time, but it starts first kick with choke and idles great without choke.
Strange problem...
I'm suspecting i have bad battery because i think it doesen't spin the engine fast as it should. I'm really new to Bergs.

Oh yes the bike has 430 hours on it and i don't know if it's been rebuilt but i guess it has been. It idles great, no excesive engine noise, just normal valve sound, shifts great, doesen't smoke and goes very good and smooth.
I'm really satisfied with my Berg so far.
On the next oil change i will inspect valve clearances.
And in the winter i will be pulling the head of to inspect valves, piston and cylinder wear.
I hope it is in good shape
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September 2nd, 2009, 09:24 AM   #2
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It sounds like you have two seperate issues.

Having to use the choke virtually everytime you kick start it probably indicates you need to increase the size of the pilot jet.

The e-start issue requires a bit more information. What happens when you attempt to use the starter and the bike does not start? Any noises? Does something spin but the motor does not turn over? Does the starter turn the motor for a second and then stop? Or is it just totally dead?
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September 2nd, 2009, 10:10 AM   #3
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I'll try with another pilot jet and i hope it will solve the problem.

E start engages but spins the motor slow(at least i think it is slow) , no noises, engine is turning over but slowly. I haven't had estart on my bikes so i don't know how fast it should turn. I'll try instaling another battery tomorow and hope it's the battery problem.

What could be the problem if the e start turns fine but bike won't start?

One more question, my bike is pretty loud and sounds flat. I looked into the silencer and there is no packing in there, is there suposed to be packing in 4 stroke silencers or just empty? Is there some performance losses if there is no packing? I know that 2 strokes without packing loose top end power but does that apply to 4 stroke aswell?

I'm sorry for my english but i'm from Europe.
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September 2nd, 2009, 10:20 AM   #4
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Good idea to start with a new battery, preferably a Yuasa YTZ7S. Also get a high tech battery charger like the Optimate 3 or 4. Keep it plugged in at all times when not riding. Before installing the battery be sure it is fully charged. If you don't battery "memory" may keep it from ever accepting a full charge.

If the e-start turns fine it should start.

I have never taken my silencers apart ( will be doing so soon) but would expect to find some sort of packing in them.

Is the bike a 2002 or 2003 model? All yellow would be 2003.
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September 2nd, 2009, 10:23 AM   #5
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you need to go right through your bike and get everything checked out. although husabutt's idea sounds good i think that the standard jetting when fresh and new is always the best. nobody as i'm aware has found better settings than those from the factory in all these years.

suggest that the float height is wrong and doesn't allow enough fuel in. so check that first. also get a new atomiser and needle as well as a quality iridium plug and set the tappets as per the 'poor starting' section of 'the doc' (left of your screen).

your battery is receiving a charge but not keeping it. get a CTZ7s or a YTZ7s and break open the battery box ever so slightly to fit it.

then you should be a lot better off and the problems may well have altered for you. if you go into gallery and into 'taffy' or 'weed' you'll see photos of tuliped valves and this is how bad they can look!

regards

taffy
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September 2nd, 2009, 10:46 AM   #6
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It's all yelow so it must be 2003.

I'll try with YTZ7 battery, i really hope it will fix my problem because i don't want to go in woods without electric start. I've had enough of kicking so far and now with left foot kickstarter i really don't like the idea of kicstarting this one in woods.

I have one more problem that really bothers me, clutch won't dissengage fully so bike stalls often, if i hold the clutch, give it a little bit of gas and put it in first gear bike starts going forward slowly. When the engine is fully warm it isn't that bad but if i stop in 1st gear with clutch in, bike stalls. What is wrong? I tried adjusting clutch lever so piston goes all the way to the end of the pump but that doesen't fix the problem. I opened the oil plug to see the clutch, clutch basket is like new, plates seem fine. What could cause this? Do i need to put new oil in the system?
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September 2nd, 2009, 02:22 PM   #7
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to be a 2003 you need to see if you have an earth wire from the negative post around the right-hand side to where it is bolted into the starter motor mounting bracket. also all 2003 models have large wheel spindles in the front wheel and the end caps are concave on each end. look in the doc and you'll see chapter one is year identity. there is a very good photo there of front wheel spindles.

let us know and then we can help you with your clutch ok?

regards

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September 2nd, 2009, 11:25 PM   #8
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I know 156% that i have 2003, everything you said is exactly what i have on the bike, i read doc and also checked VIN. Bike is all yelow and has digital speedo.
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September 3rd, 2009, 12:07 AM   #9
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in that case you have the later clutch so i suggest that you remove all the plates in the clutch and look at the steels. they are possibly blued/coloured and distorted. suggest a new clutch set. there isn't a lot else to go wrong with them. you can pull the assembly out completely and look for a washer underneath everything againbst the gearbox bearing. there should also be another stepped washer and two 'half-moon' washers between the basket and the drum. other than the slave malfunctioning - they are normally ok?

regards

Taffy
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September 3rd, 2009, 09:13 AM   #10
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also the 03 has 2 different thickness steel plates. half the thin ones go to the inside, half to the outside. thicks in the middle. don't know if that would affect your problem tho.
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