I need help please!!

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seabeast

Joined
Jan 30, 2008
Messages
17
Location
Te Anau, New Zealand
Gday fellow 'berg maniacs,

First up I love this site its brilliant

I don't know what's happened but the berg stopped on me out on a ride and now it's GOT NO SPARK!?. Its an 04' FE550e.
Leading up to the disaster the following occured: it got hot idling around whilst stuck behind some youngsters on a single uphill track. 1st gear stuff very slow. It started blowing steam out the radiator overflow so I stopped immediately. The steam died down a bit so I fired her back up and took off at a faster pace but low engine load to try to cool her down. After about 5 mins at 30-40mph it seemed fine. later when i topped up the rad it took about half a cup. 10-15mins later after a very fast hillclimb up a steep single track I stopped at the top to wait for some slow jap riders, then fired back up on the leccy start, went to take off quietly and she putted out.
Things I've checked: different plug in the berg: no spark. my plug in a different bike: good fat spark, took the plug cap off to try to arc to head: nothing, unplugged both kill switches: no spark, checked all my leads and connections: nothing seems out of place. took the ignition cover off and checked the leads and soldering and all seems fine.

How do I check the stator and CDI for failure? Anybody got other suggestions?

My jap riding mates are ribbing me for having an "unreliable foreign bike" so I need to get back out and roost them good.

Thanks in advance I hope!!
 
take the ifnition cover off and grab the flywheel with the whole of your great big hand. try and move the flywheel up and down.

you may have the right-hand main gone.

regards

Taffy
 
seabeast said:
Gday fellow 'berg maniacs,

First up I love this site its brilliant

I don't know what's happened but the berg stopped on me out on a ride and now it's GOT NO SPARK!?. Its an 04' FE550e.
Leading up to the disaster the following occured: it got hot idling around whilst stuck behind some youngsters on a single uphill track. 1st gear stuff very slow. It started blowing steam out the radiator overflow so I stopped immediately. The steam died down a bit so I fired her back up and took off at a faster pace but low engine load to try to cool her down. After about 5 mins at 30-40mph it seemed fine. later when i topped up the rad it took about half a cup. 10-15mins later after a very fast hillclimb up a steep single track I stopped at the top to wait for some slow jap riders, then fired back up on the leccy start, went to take off quietly and she putted out.
Things I've checked: different plug in the berg: no spark. my plug in a different bike: good fat spark, took the plug cap off to try to arc to head: nothing, unplugged both kill switches: no spark, checked all my leads and connections: nothing seems out of place. took the ignition cover off and checked the leads and soldering and all seems fine.

How do I check the stator and CDI for failure? Anybody got other suggestions?

My jap riding mates are ribbing me for having an "unreliable foreign bike" so I need to get back out and roost them good.

Thanks in advance I hope!!
Click to expand...


Hi Seabeast,

This is very unusual to have problems with this system, recheck the soldered joints on the stator, 04 stators were prone for desoldering, but usually on the alternator side.
Check the resistance between Red/White and Black/Red should be around 15 Ohms.
Check between Red and Green should be around 100 Ohms. (pick up)
Check the secondry resistance of the HT coil with out the cap around 5000 to 6000 Ohms.
Check the Blue feed wire to the coil and all other connections.
There is no tests you can do on the cdi, but I think you will find the fault in what I have mentioned above.

Regards

Sparks.
 
Hi Taffy and Sparks

Thanks for your replies.

Taffy: I grabbed the flywheel with my big southern hand and swung on it with all my viking strength and no movement could be felt. I even checked with a dial indicator and the needle didn't budge. My mains are good I think! (hope)

Sparks: I got these figures, 14.8ohms for the red/white to black/red, 96ohms for red/green. These seem OK?

I'm not sure what you mean by checking the secondary resistance of the coil can you elaborate please? Also is the blue feed wire to the coil a small wire that connects to the coil via a flat pin connector? I checked this it feels tight and looks ok.

One thing I did notice is a small cap screw inside the ignition cover just beside the grommet where the wires go through which holds a small pressed metal clip thing. This cap screw is loose. What does this do?

Again thanks for your help guys.

Regards
seabeast
 

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seabeast said:
Hi Taffy and Sparks

Thanks for your replies.

Taffy: I grabbed the flywheel with my big southern hand and swung on it with all my viking strength and no movement could be felt. I even checked with a dial indicator and the needle didn't budge. My mains are good I think! (hope)

Sparks: I got these figures, 14.8ohms for the red/white to black/red, 96ohms for red/green. These seem OK?

I'm not sure what you mean by checking the secondary resistance of the coil can you elaborate please? Also is the blue feed wire to the coil a small wire that connects to the coil via a flat pin connector? I checked this it feels tight and looks ok.

One thing I did notice is a small cap screw inside the ignition cover just beside the grommet where the wires go through which holds a small pressed metal clip thing. This cap screw is loose. What does this do?

Again thanks for your help guys.

Regards
seabeast
Click to expand...

Sorry I forgot to elaborate on the coil, put you meter setting on 20K, then test between the HT lead on earth, this should give you the secondary resistance.
Also check the main bunch of Brown earth wires that are near to where the Blue coil feed is.
The steel tab in the case, that is there to retain the wires up out of the way of the flywheel, in your photo the tab needs to be turned so it is pushing up against the wires.
I can't remember did you disconnect the Fill switch wire?.
Obviously I can't say 100% but if all these check Ok then it is looking like the cdi I'm afraid, but double check every thing again.

Regards

Sparks.
 
sparks said:
seabeast said:
Hi Taffy and Sparks

Thanks for your replies.

Taffy: I grabbed the flywheel with my big southern hand and swung on it with all my viking strength and no movement could be felt. I even checked with a dial indicator and the needle didn Hi Sparks

Checked the coil secondary resistance as you described and I get 5.6kohms so that seems to be OK as per the expected values. I've checked and double checked all the main wires and all seems fine.
I disconnected the kill/horn switch that screws to the same unit as the headlight and turn signals screw to. It made no difference, still no spark. I also disconnected the main kill switch that has the starter button attached and kicked it over, still no spark.

So I guess its all pointing to a dead CDI? I will borrow my mate's CDI (another FE 550 maniac) this weekend and try it.

I will let you know how it goes!

Thanks for all your help sparks, much appreciated. Cheers
Click to expand...
Click to expand...
 
seabeast said:
sparks said:
seabeast said:
Hi Taffy and Sparks

Thanks for your replies.

Taffy: I grabbed the flywheel with my big southern hand and swung on it with all my viking strength and no movement could be felt. I even checked with a dial indicator and the needle didn Hi Sparks

Checked the coil secondary resistance as you described and I get 5.6kohms so that seems to be OK as per the expected values. I've checked and double checked all the main wires and all seems fine.
I disconnected the kill/horn switch that screws to the same unit as the headlight and turn signals screw to. It made no difference, still no spark. I also disconnected the main kill switch that has the starter button attached and kicked it over, still no spark.

So I guess its all pointing to a dead CDI? I will borrow my mate's CDI (another FE 550 maniac) this weekend and try it.

I will let you know how it goes!

Thanks for all your help sparks, much appreciated. Cheers
Click to expand...
Click to expand...
Click to expand...

Seabeast another test you can do if you havn't already done it, meter out the wires that come from the cdi plug connector to there relivant point.

It just seems strange this happened after the motor got hot.

Regards

Sparks.
 
Seabeast,

Just picked up a '97 FE 600 and trying to find some info on what the common issues are. One of the things that stood out as having high failure rates was the stator. In for new tires today, the guy in the shop seems to know them well and he described exactly the same symptoms are you've had. I like being prepared, so I asked where the best place would be to get replacements and he said Nigel Bevin (HusaForce Taupo- me thinks) was da man. Although sounds like Taffy and Sparks know the score and should be able to put you right.

Cheers
Moki
 
Moki said:
Seabeast,

Just picked up a '97 FE 600 and trying to find some info on what the common issues are. One of the things that stood out as having high failure rates was the stator. In for new tires today, the guy in the shop seems to know them well and he described exactly the same symptoms are you've had. I like being prepared, so I asked where the best place would be to get replacements and he said Nigel Bevin (HusaForce Taupo- me thinks) was da man. Although sounds like Taffy and Sparks know the score and should be able to put you right.

Cheers
Moki
Click to expand...

Hi Moki,

Yes Nigel is a good lad, no bull, I have delt with him for a couple of years now, doing my SEM rewound stators.

Regards

Sparks.
 
I found why i lost spark

G'day again berg maniacs

I've found the problem of why I lost spark. I visited my mate yesterday who has the exact same bike as me and we lined them up side by side in his garage (a very healthy looking garage now with the 2 bergs and his vintage 430XC husky) we swapped bits and pieces over from his to my bike until I came across this. I call it the pulse coil. Or the pick up? I'm not sure but it picks up the pulse from the flywheel. As the pictures show, its munted! It still reads the correct resistance but is too far from the flywheel now to be able to pick up the pulse.
In one om my previous posts I've added a picture of the little clip which holds the wires away from the flywheel inside the cover. Mine is broke!
I'm guessing the clip has broken off, has been flung around by the flywheel and smashed into the pulse coil.
The only thing i'm worried about now is where did the clip go? I can't find any remnants of it in the cover so I'm assuming when i took the cover off on the track it fell out unnoticed.
So anyway I'll be on the phone tomorrow to Nigel to see what a new pulse coil costs.

Looking forward to roosting more jappers.

Cheers
 

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