Non running 2004 FE450

[Aronbaron]

Just bought this thing 2 days ago and i’m kinda lost. Previous owner said that the valve needed to be adjusted and fluids filled. The kickstart doesn’t move at all, i’m not sure it did move before i started tampering with it. The e start doesn’t do anything. I charged the battery but the button does nothing. Took of the valve covers but cant get the engine TDC, and i cant shift it up into 6th gear or any gear other than 1st. There is no oil in it so im hoping its just that. I haven’t been able to remove the spark plug since i don’t have the right socket and its tight and wires are everywhere.

 

[Taffy]

I suggest you take off the left cover and the ignition cover. at the same time, buy a plug socket as they are always needed anyway.

You need to find out if the crank is locked or what the crank turns is locked.

Taffy

 

[Aronbaron]

I suggest you take off the left cover and the ignition cover. at the same time, buy a plug socket as they are always needed anyway.

You need to find out if the crank is locked or what the crank turns is locked.

Taffy

Ok since then i’ve managed to hear the starter. But i have managed to somehow break the starter wires and my father is trying to fix that today so i hope that i can fire it up tommorow. The kick start is still stuck so we’ll probably have to open it up tommorow.

 

[Aronbaron]

I suggest you take off the left cover and the ignition cover. at the same time, buy a plug socket as they are always needed anyway.

You need to find out if the crank is locked or what the crank turns is locked.

Taffy

Hey, so can the motorcycle be started w o the stator? We re wired it but no change in the sound of the starter so now we dont know if its the stator or the kickstart being locked. Unless we learn something new the next thing will be to open it up. Does the oil need to be drained?

 

[Taffy]

of course it can be kick started!

yes it does.

Taffy

 

[Aronbaron]

of course it can be kick started!

yes it does.

Taffy

Yeah we thought it couldnt. The thing is we aint sure if the stator works as it should and the kickstarter is still locked up so we took of the LH cover and will try to see if its all right. Any tips for that whole thing? Any other reason the kickstarter would be locked up?

 

[Taffy]

so is the crank free?

 

[Aronbaron]

so is the crank free?

I believe so, i got TDC via the flywheel to adjust the valves so i think it is…

 

[Taffy]

the kick start can fall off. you will find the k/s "chewy". the way to get over it is to remove the clutch (photo the timing dots on the gears first) and then the kick start. remove the plate and then put it back but with 1mm thick washers behind it so that you have brought it out towards you. Loctite the screws.

Taffy

 

[Aronbaron]

Thank you Taffy, just watched your video on the kickstarter assembly. The next step is to remove the clutch basket right? I wanted to see what would happen if i hit the starter B now and it did sound different, it wasnt just spinning so i do think the problem is the kickstarter being stuck somehow. Any tips on removing the clutch? Never done it before so input is welcome. I. Fold down the little tabs and then i unscrew it? Do you think i’ll have to adjust the timing to get her started or will it just be fixed by the kickstarter unlocking?

 

[Taffy]

just the kick starter

 

[Aronbaron]

Hello taffy im back, finally managed to get the clutch basket off but have a new problem, i dont know how to take off the gear behind the clutch…

 

[Aronbaron]

Believe this aint right… well sht.

 

[Taffy]

that plate needs to come out 1mm. use loctite on the threads as its job is to sit there and take concussion shocks all its life.

Taffy

 

[Aronbaron]

Do i use a washer or something else? Thanks for the help i feel like its close, cant wait to hear it for the first time!!

 

[Taffy]

yes

 

[Aronbaron]

Is this okay? I feel like it needs to go further in… it spins but not that freely!

 

[Aronbaron]

I put it all together, the kickstarter was weird but it spun all the way and rotated the gears inside so i guessed it was fine. Connected everything, new coolant and oil. The kick start goes very easy lik 30deg and then stops i can force another 10deg but when i lift of i could hear a whirring sound of the gears and then nothing on the way to the top… Clutch lever also feels like sht, do i need to bleed it now since ive had taken the clutch put completely? Tnx
Cheers Aron

 

[Taffy]

Do it again, the key isn't sitting on the sledge. the clutch basket should be just 0.5mm above the gear keeping it honest.

Taffy

 

[Aronbaron]

Do it again, the key isn't sitting on the sledge. the clutch basket should be just 0.5mm above the gear keeping it honest.

Taffy

Thanks, i’ll check it out today