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  • 2 Post By polska
  • 1 Post By ned37
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February 2nd, 2018, 10:39 AM   #1
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Joined: Jun 2008
From: Simi Valley Ca.

Posts: 1,086
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I Ride: 2006 FS650e, 2007 FE550e, 2016 Ktm500Exc
2002 650 upgrades

Im looking for all the upgrades to make one better and more reliable.
I know FCR 41 carb and 04 ignition.
But as far as valves, rockers , chain tensioner or even newer cover. What is the way to go?
And of course Main bearings.
Looking for the complete solution.

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February 2nd, 2018, 01:15 PM   #2
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From: Burlington

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I Ride: '07Exc 525 & '07 FS 550.Just sold ' 08 Ktm 450 sxf.
Ah yes. It's possible and mighty expensive when done right. Spherical rollers very good. The best. But expensive to machine cases and other bits. At the same timeme do wet ignition and you double oil capacity. Like Bushmecanic did. Bump oil pressure and maybe do pressure lubrication with oil jets, again Bushmecanic done it. Microblue coating might be worthwhile as well. Just my two cents. External oil filter?Better micron rating better filtration. Have total around 3L oil and return line spraying on cam chain.
Thanks from bushmechanic and pollo
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February 2nd, 2018, 06:30 PM   #3
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Joined: Jun 2008
From: Simi Valley Ca.

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I Ride: 2006 FS650e, 2007 FE550e, 2016 Ktm500Exc
Thanks, there's an 02 650 local for $1500 thats supposed to run good. Seemed like a descent price although I've never been to serious with the 01-03s.
Other than having a spare motor. But in that case I would want it right.
Its nice that it runs good, but I wouldnt have peace knowing its not going to get the hours and reliability as
an 04-08.
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February 3rd, 2018, 08:31 AM   #4
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Joined: Dec 2004
From: back in cottonwood, az

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I Ride: '08 HUSKY te610
ha ha ha. good luck and be patient.
took me a lot of experimenting with an 02 650, but after a yamaha 600 starter, machined cam, steel sprocket, autodecomp, fcr41, upgraded rockers; it was a reliable starting rocket.
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February 3rd, 2018, 11:22 AM   #5
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Joined: Aug 2008
From: England, Southampton

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I Ride: 02 650 StreetTracker, 92 K100 Special, 92 Triumph Cafe Racer.
Worked my way through the Wiki upgrades on my 02 and its been great.
Got it starting well on the Dellorto but the FCR is a different league.
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February 4th, 2018, 01:05 AM   #6
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Joined: Nov 2001
From: Ely, England

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I Ride: Husaberg FE501e 2003
if you get all the upgrades done, the 2001-2003 650 is a brilliant bike. I have a video on the Taffmeisters FB page about all the mods you need to do to a Husaberg of this era to make it start and run well.

I'm presently taking my 'easystart' kit further and found a really large impprovement in the performance that i can't wait to pass on when it is all spot on. its all to do with the pilot jet.

I'm testing it on my 501 (2003) at the moment but will transfer it to the roadbike pretty soon (FS650 2002).

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2002, 650, upgrades

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