2003 FE650 Electric Start Wire Guage?

tdetlor · Sep 6, 2014

I want to first start by saying, I have 2 bikes. A 2004 FE450 and a 2003 FE650. The 450 starts on the button with great pace. Easily and all the time.

The 650 is a dog, it struggles like no tomorrow. It will start on the button but ive always felt the battery is nearing its end. A yuasa ytz7s. So i replaced it yesterday with a brand new Ballistic Evo 2 8 Cell battery. Nearly double the CCA.

To no avail. It cranks over at the same rate. And sounds like the battery is dieing again, weird. I put my fingers on the wire connection points and found the connection to the starter motor very hot. also at the solenoid post quite warm.

Should i be upping the guage wire to accomodate the larger bore engine?
Maybe get some 4 guage?

Ive also tried the 2004 fe450 starter motor in the 650 with the exact same results.

Or are these starter solenoids only good for so many amps to pass through them?

Thanks
Tim

Taffy · Sep 6, 2014

a test I'm hopefully doing this winter for a customer is that it might be a voltage drop at the coil. I'm going to check for the voltage drop.the second test which is proving harder to do is to gear-up the starter system.

basically, even f I add a thimble full of kickstart effort while cranking, it will start on the button.

many here have tried car batteries and thicker guage wire etc.

the other thought is the gearing of ste starter system.

basically, years ago the batteries were so weak that they geared the starter system down. the SEM ignition starts sparking at about 400rpm per minute but this is also the speed at which the starter is spinning.

so it's nip and tuck.

that brigs you up to date.

I can get a standard 650 (2001-2003) to start on the button fairly easily after I've worked on it and done my mods. it's the dell orto'd ones with the HC pistons that we can't get to start.

it would be good to find someone who would recut the teeth on the outer sprague and the smaller gear on the starter clutch. get more revs for the same speed starter motor etc.

regards

Taffy

tdetlor · Sep 6, 2014

Taffy. After I installed the fcr on the berg last week. It starts on the button pretty well. However. If I flood the engine or do anything out of correct procedure the starter slows right down. And now it won't start because the starter speed is too slow.

Does this r6 starter motor solve the problem. Or like you say. Time to gear the starter motor. Lucky I work in a machine shop.

Thanks
Tim

tdetlor · Sep 6, 2014

I noticed a draw that's taken the battery from 12.7v down to 8. When cranking. Seems way to much

tdetlor · Sep 6, 2014

Beefed up the wires to 4 Guage. Now I have the battery on a 2amp charge. See what happens when it's fully charged

husabutt · Sep 6, 2014

In 2004 the 550 and 650 models came with a slightly larger starter. To use this starter you will also need to purchase the bracket. Obviously Husaberg realized that the tiny little 450 starter wasn't quite up to the job. Many have reported good if not better results with the starter that Taffy has available. Also update to the 04-08 Decomp which Taffy also has and his modified spring. The camshaft was changed in 04 also which "may" affect starting. Try resetting your timing chain tensioner so that your timing chain is not too tight which could place drag on valve train. As Taffy stated the sem ignition is a bit of obstacle. Try pulling in your manual decompression lever, spin it up and let her rip.

tdetlor · Sep 6, 2014

Wow, while kickstarting the bike as regular procedure. And pushing the electric start at the same time, the bike fires up instantly!

I would like to get this lug to start on the button though, without hesitation.

So, New Battery ( CHECK)
4 Guage wire upgrade (CHECK)

Yet still have the slow starter. Time to upgrade.

Tim

tdetlor · Sep 6, 2014

Just a thought.

Has anyone tried throwing a 0.5 farad capacity between the battery and the starter relay?

Soak up some of that immediate draw from the starter?

Tim

2003 FE650 Electric Start Wire Guage?

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