FE650 Wiring Loom (Kick Start Only)

FraserThompsom · Apr 16, 2020

Hi Guys,

I have just bought my first Husaberg and its a 2002 FE650 but it is kick start only.

I have a base knowledge about Husabergs and lightly know my way around a bike.

It is kick start only and has no Battery, ECU, starter motor etc but I believe it has a rectifier.

I'm just looking for some advice on how to go forward with converting it to electric start?

I've bought the bike to learn more about them and would appreciate any help at all (i'm not great with terminology's either at the mo lol).

Thanks in advance guys!

Fraser

Taffy · Apr 17, 2020

My advice is to make it the best starting kickstart bike you can. that will cosst you a lot of money. the electric start cannot function unless the kickstart functions because the kickstart is easier for the engine to start.

you'll likely have distorted inlet valves that sink into the seats so valve clearances will need doing regularly. check if you have single or dual valves. it will need the later auto decomp and my modified spring. learn how to do valve clearances. always be able to morse code at the end and hear the tappets at the rear registration plate JUST.

also, that is the last year of the MX cam and on or off road unless racing the later 08 cam is far more suited to it. the jetting alters with this cam.

get the flywheel remarked and get the igniion timing done. as per videos on my facebook videos.

after the ADC the easystart kit is the next most important thing. they won't start with the wrong jetting simple as. I encourage people to go to a choke that you control and mount it up on the left bar instead of that black lever being for decomping. the decomping should be automatic and on the cam.

the carb parts wear anyway.

an iridium plug should be ready and waiting for when it is all sorted.

if and when the bike starts easily when kicking, you're ready to invest time and energy in going to leccy start. YOU NOW HAVE A PM EXPLAING ALL THE PARTS NEEDED FOR THIS.

regards

Taffy

FraserThompsom · Apr 17, 2020

Again, thank you for the advice Taffy!

That seems to be a wise idea, the bike has a sledge upgrade from yourself but I don't have a clue what it does (it also has the jetting kit from you too and the 2008 clutch).

At the moment it has a magura decomp lever and I believe the auto decomp is not connected and just taped up.

It is definitely a nightmare to kick, I have followed all of the videos and it just seems to get stuck half way through the kick (but then will fully stroke with the decomp, is this normal or have I just not found TDC and thought that i had?).

How would the 2008 CAM help more, is it manufactured differently and does it for straight in?

Really appreciate the help!

Fraser

Alfy · Apr 17, 2020

Hello! If the motorbike does not start, you can identify 3 main causes:
1) Spark. Remove the plug spark and check the spark
2) Fuel and carburation. The fuel in the tank must be recent, preferably from today (not a month ago). The fuel in the carburetor tray should also be recent. I advise you to empty the tank and the carburettor (remove the cap under the carburetor) and drain the old fuel. Then check the slow jet because it could easily be blocked. If necessary, change it with an original spare of the same size. Also check that the carburetor is not dirty with oil from the filter side: the oil to grease the filter or the cloud of oil that condenses inside the frame can clog the air passages that feed the minimum circuit and the maximum circuit.
3) Compression. Too much compression does not make the engine fast enough, so kickstarter does not really go down. In this case the fault lies with the lobe of the automatic decompressor that is worn out or the return spring that remains open. Little compression is due to valves out of tolerance and in any case you can check it from an kickstarter that offers little resistance to the foot.

See also:
Husaberg Motorcycle Poor Starting Problems | Husaberg Wiki

Alfy · Apr 17, 2020

I try to be synthetic. You have too much compression. Causes: decompressor or valve clearance out of tolerance

FraserThompsom · Apr 18, 2020

Hi guys,

Good news (bad news for my dignity), I was being special with the kick start, I was not truly finding TDC when I though that I was.

I'd kick the kick start half way through and it would stop completely, so I let the kick start rose yo the top and decompressed it by an inch and away she went.

This morning she went on around the third kick.

In regards to the electric start, I have found this for sale (as per my private message Taffy).

Would this the past of the loom I need? (Just collating parts at the moment until I collect them all lol)

Thanks again!

FraserThompsom · Apr 18, 2020

There is this one too but have been told its for an 04-08 FE650 and believe this is the whole loom rather than just the ignition side.

Taffy · Apr 18, 2020

the first one is for an FC550 and therefore was never electric start. electric start has to have an 8 wire Ignition Module whilst the MX has 5 wire. so it wouldn't start on the button.

and as you say the other one is wrong era.

Taffy

FraserThompsom · Apr 18, 2020

Thanks Taffy,

When you say it was never electric start, does that mean that this is just a restarter?

Fraser

Taffy · Apr 18, 2020

No, I said that that coil (ignition module is the correct name) is from a MXer and they never had ES. you need an 8-wire I.M for electric start to function. one of the wires is connected to the solenoid and is a boost wire while you are pressing the ES button.

regards

Taffy

ede · Apr 22, 2020

Hi FraserThompson,

the pics you've attached with this message look suitable for an e-start conversion to me. Even though Taffy mentioned it will not provide e-start I guess it will work:

Ignition module has 7 Wires + 1 ignition cable = 8
The coil with part number 250 289 01 was the ignition module for a 2002 FC 550

When you check the wiring diagram inside the parts catalogue page 55, you'll see that the FCe/FXe wiring harness is basically the same as the FSc/FC wiring harness, only with the blue-white cable between starter button and ignition module, closing the starter motor relay (contact pin 1). You'll need a switch to turn on/off the battery circuit (usually the key switch), a regulator/rectifier and off course, the generator needs to have 2 yellow and one blue wire for charging the battery. The FSc/FC-stator only comes with 3 wires (red, green, black) for ignition only, while the other stator has the additional 3 wires.

Besides that, a battery, the starter-motor, a starter-relay and a 10A fuse in case the relay pulls to much current, to not damage the battery. That's it! When you'll go with the harness from the pic you'll have the half of the parts.

Besides that I have to mentioned that Taffy is right when he says, you should make a good kickstarting bike out of it. My e-start also only works when the engine is hot. For cold start I use the kickstarter only! All the e-start stuff is expensive and when the friction clutch gear between starter motor and clutch basket is not set to the right momentum, you can severely damage your gears... happened to me once!

Regards,
EDE

FraserThompsom said:
Hi guys,

Good news (bad news for my dignity), I was being special with the kick start, I was not truly finding TDC when I though that I was.

I'd kick the kick start half way through and it would stop completely, so I let the kick start rose yo the top and decompressed it by an inch and away she went.

This morning she went on around the third kick.

In regards to the electric start, I have found this for sale (as per my private message Taffy).

Would this the past of the loom I need? (Just collating parts at the moment until I collect them all lol)

Thanks again!

FE650 Wiring Loom (Kick Start Only)

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