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May 29th, 2020, 10:49 AM   #31
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Back at it.

I'm starting to think the cam is 180 degrees off. Would it be possible to run the bike (albeit barely)?
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May 29th, 2020, 11:30 AM   #32
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the cam can't be 180d off.

Taffy
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July 15th, 2020, 01:51 AM   #33
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This bike if genuinely getting on my nerves.

Yesterday I spent another day of tinkering with it. This time removing the cam once again (3rd time) making sure everything was lined up and put back together, set the valves and ignition according to everything I've learned. Removed carb again and cleaned everything for the 10th time. The bike started up after a few tries, no idle, ran for 30 seconds then bogged down again.

However. I'm starting to suspect I'm getting erratic spark with the plug installed. Once I have it out and ground it on the cylinder a spark is visible, but the reason the bike won't run HAS to be because it's not firing a spark properly with the spark installed (which can't be seen of course). So I'm thinking about replacing ignition coil and possibly CDI (is there one on my 2002 FE650? Can't remember atm)

Of course another problem occured yesterday too.. The starter is replaced to a heavy duty one from Taffy according to the previous owner. Yesterday it just started clicking even though I have 12-13V on the starter side of the relay/solenoid. No wonder since I've cranked it probably hundreds of sime by now. So a new starter is probably due too..

In summary: I need an ignition coil and a new starter. I'll wait with replacing the CDI until I've tried with a new coil.

Is this something you could help me with @Taffy?
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July 16th, 2020, 12:38 AM   #34
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well yes I can help you with those items but the biggest help i can give you is to say 'no' you're probably wrong and should save your money.

you can buy a spark checking tool and they are worth their weight in gold. best tool I ever bought.

this one is called the Blue Point (they are part of snap-on) Copquick probeVS
and they are non-invasive.

OK, when this happens to me, I pour fuel into the rubber boot and let it go right up to the two tiny holes in the front face of the carb.

your slide should be open 6-6.5mm

you must kickstart it at the beginning. use a solid platform like a milk crate or a jack-in-the-box workshop stand and a pair of MX boots. even trying this without MX boots; I can't start them!

cheers

Taffy
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FE650 2002 - Won't run properly-blue-point-copquick-probevs.jpg  
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July 17th, 2020, 01:19 PM   #35
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Thanks for your advice Taffy. I'll definitely get a spark tester before I start replacing ignition parts. I really think my problem has to do with intermittent spark. Either the coil, HT lead or SEM unit.

The bike is fitted with your "beefy" starter, auto decomp and easy start kit and has always started fine with e-start only. Now that the starter relay is clicking but the starter is not doing anything I'm guessing the starter needs replacing regardless. I'll start with tearing it down to find out if it's fixable first.. quick question: Is the starter removable without removing the clutch cover?
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July 18th, 2020, 01:38 AM   #36
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you can take the starter motor off without entering the engine.

it sounds to me like the HT cables are making a pooor connection. rub them all down with something like emery cloth and refit. that clicking will be that or the battery but I doubt that it is the starter motor.

Taffy
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July 21st, 2020, 11:22 PM   #37
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It wasn't the starter. I took it out and tested it in the work bench and it spins like it should. It's the relay thats acting up. When measuring it's working fine, clicking like it should and sends power through. Re-mounted everything on the bike.

Went through the cables from the ignition coil (red SEM coil). Everything looks OK.

Figured I'll try starting the bike again (for the 1000th time). First it was just clicking but all of a sudden started cranking again. Lo and behold, THE BIKE STARTED. I quickly took it off the lift, keeping the revs up so it wouldn't die, and rolled it out on the street. Kicked in in gear and took off. It pulled like it should in first, second and third. Turned around and stopped outside my garage wishing I had a screwdriver with me so I could try adjust the carb and get some idle. I didn't, so the bike died when letting the throttle go.

Tried starting again. Didn't start. Puffs and bangs but no start. Charged up the battery and came back a while later. Cranking forever. No start. Just like before. Tried again and the starter relay started clicking again. Went to bed.

Last edited by herrlantz; July 21st, 2020 at 11:32 PM.
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July 22nd, 2020, 04:44 AM   #38
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idle could be too low? try getting the slide mouth up 6.5mm

Taffy
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