Shut down at 60mph after rebuild, won't restart anymore - 2011 FS570

What can I say anymore. I think this bike hates me. Got it back on the road again early this year after new cam failure. The smaller cam bearing surface worn down in the blink of an eye. Had the bearing surface laser welded back to new tolerances and put it back in, and also installed new bearing in the head. Everything worked perfectly for 15mins, and then the cam shat itself again this time by breaking a piece from exhaust lobe.

I tore the motor down this time and prayed that I didn't bust everything inside it. No visible wear anywhere, crank cylinder,piston, head, cases, transmission, oil pump etc. looked perfectly fine. Put new conrod in it just for safety reasons. Got the crank back together with better tolerances than it was. Used old mains as the motor only had 117hr and they looked practically new. Main bearing runout less than 0.06mm, crank runout 0.03mm, crank web width 63mm +/- 0.02mm, rod end play 0.50mm.

Started to piece it all back together then. Head was shaved 0.06mm, ceramic coated the combustion chamber and used old 25hr head gasket. Stock cam went in as I was fed up with the useless welded and ground cams that all failed. Started it up and it immediately fired into life. No abnormal noises or anything. Ran perfectly and no leakages was found. Took it for a test ride and managed maybe 15mins this time and it just shut down when cruising in sixth at 100km/h.

Now it won't start anymore...I get spark and fuel when disconnecting TPS and checking into intake tract while throttle is open. Cranks normally but won't do a thing other than rarely a very loud backfire. At first I thought it was fuel issue because I couldn't see the injector firing when cranking. After disconnecting the TPS I see fuel mist from injector so that can't be the issue...?

So now I'm thinking the spark must be out of time, or I have lost compression? It cranks normally with the spark plug in and very freely without so I guess it has normal compression.

I'm getting really frustrated with this bike. It has seen maybe 20hours in the past 1 and half year.

Do a pressure test see what that will tell you. Glad to see you back.

Glad to read from you...
Sorry I cant help you I am curious whats the cause of the problem.

Fueling for the ECU - did you return to a stock map for the stock cam or are you still running a modified map for the Thumper cam? If you are using the stock cam w/ mod map it may not be getting the correct fueling. Just an idea.

I don't mean to be a buzz kill but your shut down symptoms sound identically to my 570 when the oil pump failed = no compression, I hope the cam issue doesn't follow me as I have the same cam as you have so I hope it's some thing like TM described.

Alaska what damage happen to your bike. I have a FX450 got it not running might be the same as yours ?

Oil pump failed due to plastic gear/drive failure. The bike was warmed up and about a mile down the road doing 45mph going 4-5 gear engine stopped no noise, no smoke & 2100k oil changed over every other ride. The bike would turn over normal except backfiring now and then looked at every thing possible but piston/rings were toast and almost ruined the cyl. I've owned a lot of bikes and had the engine let go before and it was never quiet or no smoke not pouring out. I am almost ready to take it on it's 1st run on new engine so hopefully all is good.

Is there any possibility to install the oil pump incorrectly?
I can not see that happening if you want the shafts and rotors installed so the cap and plastic gear drives fits back.

I don't have a compression tester that fits in the berg head. If it really is oil pump issue and it ruined my fresh motor I'm done with the bike. Built it back slowly so I could catch any mistakes while assembling it back.

Crank is locked at tdc. Is this correct timing for the crank position sensor...?

I removed the flywheel nut and the woodruf key is in place, and the rotor haven't slipped. I get serious backfires now when cranking with a new (used) spark plug. Just backfires.. nothing else.

Aww crap..... tried cranking it few times and heard a chirping like something snapped. Now it cranks likes theres no compression.

Great...time to tear apart the engine again.

maKe said:

Is there any possibility to install the oil pump incorrectly?
I can not see that happening if you want the shafts and rotors installed so the cap and plastic gear drives fits back.

I don't have a compression tester that fits in the berg head. If it really is oil pump issue and it ruined my fresh motor I'm done with the bike. Built it back slowly so I could catch any mistakes while assembling it back.

Click to expand...

The pump's are problematic as the KTM 530's and could go bad with something like gasket material getting in the right place at the wrong time or possibly the pickup coming loose.

Crap for you hope it's a cheap EZ fit for You. Will be opening up a FX450 soon in trying to get as much information as I can be for I do.

Have you checked the oil squirter that mounts to the case - the one that squirts under the piston? Could it be plugged and not getting oil under the piston?

Bummer about the motor.

Torque Monster said:

Have you checked the oil squirter that mounts to the case - the one that squirts under the piston? Could it be plugged and not getting oil under the piston?

Bummer about the motor.

Click to expand...

Exactly I hooked a drill to the pump and spun it around 3500rpm and Nada out either squirter.

Wohooo....

That's brutal.

No oil to the piston surely. I feel the pain.

Still somewhat unclear what caused the piston seizure. That was intake skirt in the pic. Exhaust side seemed untouched. Intake valves leak now, so might need to cut the seats if they are badly hammered. Hopefully I can reuse the valves. Can the titanium intake valve seat surfaces machined out, or are they trash can stuff if they have wear?

Oil squirter wasn't blocked and oil flowed freely when testing with compressed air. Head was full of oil and rocker shafts also. That seems to indicate oil was flowing.

What troubles me is that the suction side oil screen (the one near oil drain plug) was full of crap that blocked the screen completely. Not aluminium mostly as it was catchable by magnet. Felt like a silk screen or some sort cloth. Found a small piece of that stuff in the crankcase too. Oil filter was clean and oil also.

I'm starting to think that the ceramic coating that I applied in the head caused this. As it was clearly flaked off on most spots. The ceramic on the piston crown was also flaking. The bits and pieces were captured between piston and cylinder, and the rest is history...

Cylinder looks like it's reusable. Scuffed the aluminium what was left of the piston skirt off from cylinder walls, and found no markings or scratches whatsoever. Need to check plating condition and bore with bore gauge before final decision.

610 or similar motor is tingling on my back, but I'm not sure if I have faith in the bike anymore until I can be sure of what caused the failure this time.

stay positive dude you had your share of bad luck with this bike you got a lot of time/money/effort invested it would be a shame to give up now.
Hope you can enjoy your wonderfull bike again soon

A couple of weeks ago I contacted fp engineering about the big TB do you mind me sending you PM because my tuner said some things about it that I want to verify with someone who has actual experience with it...

Ps if you want you can try my ecu with the higher rev limit I got from fp engineering specialy mapped for big tb maybe wit the higher revs you can get to the magic 70 hp

Thanks mate for the positive feedback! I'll try stay strong and not give up too easily.
Hit me up if you have any questions! I'll try to be as much help as I can.

Very interested to try the ECU. I had similar plans with my stock ECU that I would flash 450fx file in it with 11k limiter. Do you still run stock ecu or aftermarket? The GET ecu is the only thing I'm missing. For now I'll try to get the bike back on the road. Found my stock piston and rings inside the garage. Time to do hi-comp version from that. Deck the cylinder so the piston sits above deck slightly and aim for close to 1mm squish. Might have to put the piston on lathe to reduce the dish and lower the cc. Have to watch out top ring to piston crown distance not getting too close. Have one modified cam still left that I think I'm trying to get work. The decomp lobe needs some machining and have to check also cam base circle runout. First cam version was horrible so much valve train noise.



I've had some bad luck with my toys this year, and been out of the game for the most part of the year. I crashed my pride and joy 4 wheeled supermoto early this year after most of the snow was melted. Now it has been in a body/paint shop for 3 months and still not finished completely...

Bought this thing last year from Japan, because I like to go sideways with more than 2 wheels also. Best decision after the Berg.