Dell Ortos 2001-2003. Starting sorted

I've been working on an answer to starting issues for over 15 years now and pretty much have it nailed down. especially when I fit a Keihin carb to the earlier bikes instead of the dell orto.

but customers pay for the bike they bring in to start and not for a conversion to FCR! and after all, the manufacturer fitted the damn thing anyway didn't they?

as usual, if you modify the starter gears, the decomp or the tensioner blade it is 'the norm' and immediately dismissed - on the back burner, forgotten.

the carb though, well if the bike doesn't start it must be the mechanics fault, the factory did everything else on the bike right? so it's just you fouling up?

work has centered around the fact that Husabergs have to have everything else done before you look at the carb - and this is true! and I'm ideally placed to do it.

the carb
it seems you can't touch the throttle and 'catch' or 'hook' the engine into starting? that like a flightless chicken, it can sqwaurk but not take off.

so with a few customers and a few hunches, just lately I've been getting great results in starting the bikes on the dell orto with some new settings, drilling and filing.

unfortunately, I have two reasons for not completely disclosing what I've learnt....

the first is commercial. as you can imagine, it is a small niche market and I make my living mostly out of just these bikes. so I need to do the work.

most of all though, I need to go one-to-one with the customers for a lot longer before I have an answer for one and all.

just lately the carb spruce up kits have been going well but I hear all the time from people that are coming to me for the first time that they are having terrible starting issues.

this kit might be good for them but the feedback is no good if the rest of the bike is out of tune.

SO I SUGGEST IF ANYONE HAS A HUSEY IN A GOOD STATE OF HEALTH AND WANTS TO GET THEIR HUSEY STARTING ON THE BUTTON WITH THE DELL ORTO FITTED, DROP ME A LINE AND I'LL TRY THE NEXT STAGE WHICH IS TO REPAIR THE CARB FROM A DISTANCE.

we'll work close together and i can send you parts if you are having issues.

can we get 2-3 volunteers?

people with all the ususal tricks done?

regards

Taffy

bump

kits should be available for this in about 2 weeks time OK?

it would be nice to have got some site members involved for direct feedback.

regards

Taffy

Hi Taffy:

Thanks for working on these Dellorto kits. Its the off season here in the inland San Diego area. Almost all of the riding here is desert. Its mid summer now so it will be a few months before we can ride again. Just wanted to say that I did take notice of your original post and will definitely check out these carb kits for my 01 470. I am too busy with work (and its just too friggin hot right now) to give you any constructive feedback or do anything but drink beer and lay around the pool.

Just an FYI, I have a 95 ATK with a brand new in the box 600 Rotax motor that needs to be installed. This is one of a few projects I have. The ATK's have a small but loyal following here in the U.S. and these motors use the Dellorto carb too. From what I have seen on the net the U.K. has a healthy interest in CCM and Armstrong / Harley which also use the Rotax motor.

Keep up the excellent work! The Husaberg community owes you a huge debt for all of your efforts. I hope that you continue to "wear the robe" for a long time.
Eric

P.S.
I received the swing arm bearing kit in good order. Thank you.

cheers Eric

I llok forward to helping with the 470. leccy boot right? mmmm? rare!

the 470 is one of the few engines I've been able to help the customer but as usual , when they are happy, there is NO COMMUNICATION WHATSOEVER!

as for the ATK, just take it one step at a time on a diagnose one at a time jobbie!

regards

Taffy

Having owned several Huskys with the Dell and an ATK 605, I can say they were all pretty easy starters compared to the Bergs of the same era. I have to assume this is likely due to their mild state of tune, low compression (10:1-Husky, 9.5:1-ATK) and mild cams vs. the more race spec Bergs.

the reason so many people went to the Keihin carb is because the jetting is so wrong on the dell Ortos. your other bikes prove that it can be done.

I always consider 'mild' or 'wild' state of tune to be associated with cam timing. whilst not mold, in no way could you call the Husaberg cam timing 'wild' either.

they should start on the button....

regards

Taffy

Hi Taffy. I too have taken notice of this thread but haven't spoken up because my 650 still isn't running.
I would love to work with you in getting the stock Del'Orto sorted once the bike is ready to ride. I just haven't had the time or money to invest in it yet.
When I get to that point and if you're still wanting to work with someone then, I'll be happy to oblige.

And thanks for the quick shipping of the decomp assembly.

Bruce

Hello Bruce

emphasis here (to truly help get this right) has to be on anyone with electric start as it is so marginal with these bikes isn't it?

the stuff I'm looking at being right is as follows OK?
later auto decomp that works properly
the ignition timing line on the stator being 1mm to the left of centre and that using a strobe, the ignition timing is 6d or 12d BTDC.
that you really need a 2003-2008 cam in there (already in the 2003) called the '08' in all models except the 400.
starter repair kit
your dell orto needs to have a good atomiser and needle in it. nothing to do with clean! call it my 'spruce up kit', call it what you like. suggest 40 choke jet and new fuel valves.
manual choke cable on the left bar. NOT the dell orto on/off that comes srandard.
Iridium plug like the IXU24 by Denso or the DCPR8EiX from NGK.
beefy starter
CTZ7s or YTZ7s battery (or Lithium Ion of course!)

other things that really help and all 'good' engines will have are:
DVSK
inlet valves not sunk
exhaust valve seats not tipped
reasonably new cam chain

not a lot we can do about the 2001-2002s that have a shagged little end and are using a drop of oil etc...

this is about getting ALL the Husabergs starting BTW? the 400s especially!

regards

Taffy

Yes please

I have bought a few things off your site taffy great service and help . I can now start my bike but with luck Sometimes starts right away sometimes I kick till I am exhausted . Have upgraded starter new starter clutch sprague and auto decomp bike is a. 2003 650 fe . I would love to ride this before end of summer what do I do now ?:cold:

pretty much as above please?

every little helps. between what Brucifer says he has done and what I say he has missed!

regards

Taffy

taffy, I will go over bike then contact you thanks Andrew Folcher

I'm Game to try it.

Taffy,

I recently got a 2001 FE400E. Previous owner got it in a trade. Wouldn't start and I got it cheap. Has had stator and flywheel replaced. Found aluminum bits in the fine oil filter. Opened it up and found the cam chain rubbing the case. Pulled head and found a new piston and new intake valves. (Shinny new, like never run) Pics attached.
Replaced cam chain and a new tensioner blade. cam sprocket had already been changed out to steel. I modified the auto decompression weight side on the lathe so lobe engages fully in the slot. I also tightened spring 1 full turn.

I had issues setting the intake valve lash, as couldn't loosen it enough to have any gap at all. New valves may be longer? Had to take a little off the caps with lathe, also opened up the bottom of the rocker a little to allow caps to come up a little more. Got it set now. May be the reason it hadn't run since new piston and valves installed.

Tried to modify the kick start sledge. But I think I ground it back a little too far. It engages right at the top and is hard to get moving without decompression lever pulled. Sometimes sticks halfway up after kick now.

DelOrto carb was very clean and I installed new iridium plug.

No luck starting. Was ready to part it out or junk it. Seriously. Bruised leg from kicking it over! Toasted the battery I think cranking on it. Hooked up a watercraft battery with cable extensions. That gave it enough juice to turn it over. About one in 4 times the starter would actually engage and turn it over. Finally used my hand as choke over carb as I cranked it. that pulled in enough fuel I finally got a pop out of it! Kept trying and finally got it to fire off! Was thrilled to hear it roar. Interesting, that after it ran I let it cool off overnight, and the next time I hit the starter it engaged and cranked for 5-6 seconds until it started. Maybe getting the oil circulated helped the sprague clutch to engage?

Now waiting on the YTZ7S battery. Also have an R6 starter on the way. ZERO luck starting it on kick. Not even a pop. I'm 5' 8" 145 lbs. Need to use kick stand so I can jump on it to turn it over. This bent the kickstand out, so now I will have to weld in a plate to strengthen it. I have an 81' Honda XL500s that I can start no problem, but this Berg has a LOT more compression.

I am quite interested in your mods if it can help me get this thing to start up easily.

Let me know.
Greg

Greg, greg, greg, greg, greg!!!!!!!!!!!!!

read the beginning and who this is aimed at fella.

so right now I need to send you an experimental jetting kit like I need a hole in the head!!!!!

you don't need it either. you wouldn't know what is right and what isn't about your bike.

regards

Taffy

Laffy Taffy

Given the HUGE amount of people clamoring to get on your Beta test list Taffy, I thought I might be able to sneak into the pack without you noticing. Guess I couldn't get it past you. My ignorance revealed itself. I wasn't expecting a free kit here. I have no doubt that you know these bikes inside out. It is your business. I have an occasional evening or weekend to tinker with them. Is there a Husaberg wizardry class I can pickup to learn the magic? Was trying to use the Forum here to help with my ineptitude.

I would assume (I know what that stands for) that your kit is going to be provided to anyone who can pony up the $ for it, Or are you going to have a pre-qualification process to see if they are competent to install it? I think the real test of your kit will be when it is in the hands of someone like me who knows almost enough to be dangerous. Install the kit and is should be better then it was.

I really appreciate the knowledge that you share with so many on this forum. I have learned a great deal by reading the Owners Doc and know that you contributed much to that. You are very abrupt with many on here, and I am certain that it really hurts your business. What do you suppose the chances are that I will purchase anything from you now? I know, just one dumb guy. We add up though, and you are offending many. How big do you think the market is for 10-15 year old bike parts?

I'll fade back into my nothingness now, but last thought:
You can become the tallest tree in the forest by growing that way, or by cutting down everything else around you.

regards,
Greg

fe400e cold starting

hi Taffy,
im interested in these "spruce up kit" I have recently bought a fe400e 2003 on 52 plate that is very difficult to cold start. A spray of engine start on the air filter and roars into life.
Let me know more details and where you are based,
David

we have put this up about an hour ago,
Husaberg - Dell Orto Easy Starting kit - Keihin Carb | eBay
what a small world. I'm 60 miles north of you at Soham between Newmarket and Ely in Cambridgeshire.

basically, we decided earlier today to just say what it is we're doing and that is to put a brand new /50 (that is 5mm) slide in. we can offer an exchange on your old one if you want to let it come this way. what it doesn't tell you is which pilot jet you need and so we are building up a picture of which pair of PJs to send a customer with the slide. what hurts is that everybody's state of tune is usually AWFUL! THE DELL ORTO IS JUST THE CANARY NOT THE POISONOUS GAS!

we sell the slide for £20 less than dell oroto want and throw in an extra pilot jet for free. on top of what you see in the advert we can also do a manual choke lever and cable to go up on the bars. here at our workshop we convert all bikes to only run with a cmshaft mounted and correctly working automatic decompressor. that leaves your left perch lever free for other things if you'd rather commit to that.

we are getting an olf FE400e running today and the bloody thing is real lazy on the starter motor so we'll have to investigate. could be a lazy starter, a battery that was never up to stuff. done the connections - it can happen!

if I can help - let me know?

cheers

Taffy

jetting

hi Taffy,

The Berg fe400e that I'm struggling to start was bought with a new Pilot and needle jet, these parts were bought from you under your recommendation.
With regard to the carb mods what else is supplied in the mod kit as would like to complete fully but less the parts already fitted?
As im fairly local to you maybe a visit could be beneficial with the Bike, im on a fairly tight budget with this bike so please advise on approx. costs for parts and labour.
Please PM me.
Thanks Again.
David

well first of all the 400 from last week. I told Stephen (our main mechanic) that we should look at the white boost wire and the grey to see what they were doing. phuqme if they weren't cross connected. when we put them right and hit the button the starter motor flew and the bike started straight away.

when warm, you couldn't actually hear the starter motor it just ran. I got this now and again and it's sweet when it happens!

you're saying that you have the PJ and the atomiser right?

you can have the price of those items taken off no worries.

I'm not going to quote any prices on work here. too difficult. call me for a chat.

Taffy

Just to let you know that yesterday, we had one of our old Husabergs back and fitted the /50 slide and other kit stuff. IT IS AN '03 but it started so quickly that you couldn't hear the starter.

it looks like we're getting them really licked now. the 470 two weeks ago and the 650 yesterday. the extra effort from us and the money it costs - was worth it I think....

regards

Taffy