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September 16th, 2015, 05:26 AM   #1
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Shut down at 60mph after rebuild, won't restart anymore - 2011 FS570

What can I say anymore. I think this bike hates me. Got it back on the road again early this year after new cam failure. The smaller cam bearing surface worn down in the blink of an eye. Had the bearing surface laser welded back to new tolerances and put it back in, and also installed new bearing in the head. Everything worked perfectly for 15mins, and then the cam shat itself again this time by breaking a piece from exhaust lobe.

I tore the motor down this time and prayed that I didn't bust everything inside it. No visible wear anywhere, crank cylinder,piston, head, cases, transmission, oil pump etc. looked perfectly fine. Put new conrod in it just for safety reasons. Got the crank back together with better tolerances than it was. Used old mains as the motor only had 117hr and they looked practically new. Main bearing runout less than 0.06mm, crank runout 0.03mm, crank web width 63mm +/- 0.02mm, rod end play 0.50mm.

Started to piece it all back together then. Head was shaved 0.06mm, ceramic coated the combustion chamber and used old 25hr head gasket. Stock cam went in as I was fed up with the useless welded and ground cams that all failed. Started it up and it immediately fired into life. No abnormal noises or anything. Ran perfectly and no leakages was found. Took it for a test ride and managed maybe 15mins this time and it just shut down when cruising in sixth at 100km/h.

Now it won't start anymore...I get spark and fuel when disconnecting TPS and checking into intake tract while throttle is open. Cranks normally but won't do a thing other than rarely a very loud backfire. At first I thought it was fuel issue because I couldn't see the injector firing when cranking. After disconnecting the TPS I see fuel mist from injector so that can't be the issue...?

So now I'm thinking the spark must be out of time, or I have lost compression? It cranks normally with the spark plug in and very freely without so I guess it has normal compression.

I'm getting really frustrated with this bike. It has seen maybe 20hours in the past 1 and half year.
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September 16th, 2015, 06:17 AM   #2
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Do a pressure test see what that will tell you. Glad to see you back.
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September 16th, 2015, 10:41 AM   #3
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Glad to read from you...
Sorry I cant help you I am curious whats the cause of the problem.
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September 16th, 2015, 11:05 AM   #4
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Fueling for the ECU - did you return to a stock map for the stock cam or are you still running a modified map for the Thumper cam? If you are using the stock cam w/ mod map it may not be getting the correct fueling. Just an idea.
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September 16th, 2015, 01:11 PM   #5
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I don't mean to be a buzz kill but your shut down symptoms sound identically to my 570 when the oil pump failed = no compression, I hope the cam issue doesn't follow me as I have the same cam as you have so I hope it's some thing like TM described.
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September 16th, 2015, 05:57 PM   #6
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Alaska what damage happen to your bike. I have a FX450 got it not running might be the same as yours ?
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September 16th, 2015, 07:08 PM   #7
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Oil pump failed due to plastic gear/drive failure. The bike was warmed up and about a mile down the road doing 45mph going 4-5 gear engine stopped no noise, no smoke & 2100k oil changed over every other ride. The bike would turn over normal except backfiring now and then looked at every thing possible but piston/rings were toast and almost ruined the cyl. I've owned a lot of bikes and had the engine let go before and it was never quiet or no smoke not pouring out. I am almost ready to take it on it's 1st run on new engine so hopefully all is good.
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September 17th, 2015, 01:07 AM   #8
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Is there any possibility to install the oil pump incorrectly?
I can not see that happening if you want the shafts and rotors installed so the cap and plastic gear drives fits back.

I don't have a compression tester that fits in the berg head. If it really is oil pump issue and it ruined my fresh motor I'm done with the bike. Built it back slowly so I could catch any mistakes while assembling it back.
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September 17th, 2015, 03:53 AM   #9
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Crank is locked at tdc. Is this correct timing for the crank position sensor...?

I removed the flywheel nut and the woodruf key is in place, and the rotor haven't slipped. I get serious backfires now when cranking with a new (used) spark plug. Just backfires.. nothing else.
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Shut down at 60mph after rebuild, won't restart anymore - 2011 FS570-20150917_134520.jpg  
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September 17th, 2015, 04:10 AM   #10
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Aww crap..... tried cranking it few times and heard a chirping like something snapped. Now it cranks likes theres no compression.

Great...time to tear apart the engine again.
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2011, 60mph, anymore, fs570, rebuild, restart, shut



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