04 Berg service-need to knows

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S

SpikeHammer

Joined
Jun 7, 2002
Messages
260
Location
UK
I'm about to service my 04 Berg (newish to me) so could do with any advice on potential issues. i.e. are there any mistakes (measurements etc) in the manual that I should be aware of.

Any quick wins, must do fixes etc.

The bike has done about 20 hours ( all in the Peaks, UK) since it's last service.

Any pearls of wisdom from Taffy et all greatfully recieved.
 
what level of service are you doing? only 2 issues mine had (has) are the lousy solder connection on the stator for the alternator, and the weak starter torque limiter.
 
spike

welcome home mate! long time no see!

i have no pearls of wisedom mate because anything i know i put in the doc.

i don't do much of the ancillaries but i still get a buzz from upgrades, mods,tuning and suspension.

keep here coz we need you to come over to the IoM in August '09.

regards

Taffy
 
change the oil and filter constantly , it only holds 900 ml and you would like your berg to serve you well . clean the air filter , check the valve clearance and now for the big one ....

check the wear on the cam chain , this is the 04 model and it would be a good idea .
 
Hi Spike,

Before I answer your question, how many hours total are on the bike?

What size is it?

And, finally, is it totally stock? Jetting, suspension, etc... details please.
 
Hi Taffy, I've been back for a while, never really left in my heart of hearts... :)
Still got the 2 x TM's and 2 x Cannondales as well as a BMW Adventure now.

Dale, the bike has 127 hrs on it and is an 04' 450FE. Bog standard with no issues.

It starts well both kicking and off the button.

It's had oil changes every time it's been out with me i.e. approx every 7-9 hours (5-7 actually riding). I use a high grade fully synth and it's also had a new oil filter every second change. The air filter is chnged every time and I'm about to switch over to No Toil ones as I use them on all my other bikes.
There has been no sign of any metal in the oil to speak of when I've made the changes.

Just looking to tweak it to it's best whilst it's apart really.

btw I've also got a Rekluse to fit to it at the same time.
 
All the service has been done, no major issues or adjustmenst needed.

A Rekluse is now fitted and was brilliant this weekend as I used the bike to do about 200-250 miles over/through and around Salisbury Plains.

Just needs another oil change, filter change and air filter change after being drowned about 10 times in really deep tank tracks full of water..!!!

Both Bergs (FE450's) on the trip performed faultlessly unlike some of the others: :)


XR400....bloody kickstart issues as normal (why do people bother with this bike?)
KTM LC4...blown fuses, flat tyre etc
RM 250...ran out of fuel
KTM 450's....both snapped chains
CCM's...three sets of blown fuses due to the wet conditions
 
Maybe an appropriate sign for the Berg's in the old days...but not now...:)

DSCN2846.jpg



Mine and Paul's Berg's are in these somewhere...very wet, muddy and slippy riding with 200+ miles over the two days

webcimg3964ad1.jpg



webcimg3995xi9.jpg




webcimg4004ck6.jpg




One broken KTM...:)


DSCN2845.jpg



Another broken KTM...:)


DSCN2847.jpg
 
SpikeHammer said:
All the service has been done, no major issues or adjustmenst needed.

A Rekluse is now fitted and was brilliant this weekend as I used the bike to do about 200-250 miles over/through and around Salisbury Plains.

Just needs another oil change, filter change and air filter change after being drowned about 10 times in really deep tank tracks full of water..!!!

Both Bergs (FE450's) on the trip performed faultlessly unlike some of the others: :)


XR400....bloody kickstart issues as normal (why do people bother with this bike?)
KTM LC4...blown fuses, flat tyre etc
RM 250...ran out of fuel
KTM 450's....both snapped chains
CCM's...three sets of blown fuses due to the wet conditions
Click to expand...

If you run one vent tube from each vent of the carb (there are two vent tubes to each vent) to a high place on the chassis and bend it over like a sheep herder's pole, but not kink it, you will find that deep water crossings approached at reasonable speeds will not drown the bike out.

I have had trouble with my bike cutting out crossing deep water and that's b/c all the vent tubes are under water so the float bowl gets vacuum locked. Put your bike on a stand, start it and let it idle, and just dip all the vent hoses in a cup of water and the bike will shut off pretty quickly. So, I just ran one of the tubes up on top of the rear fender under the seat and this cleared that up. You'll also keep from sucking water into your float bowl this way during wet riding.


That's some beautiful country you're riding in there, great pics. there is a marine base on the boundry on one of my main riding area's, so I'm familiar with that type of sign too!

One thing, if your valve lash ever starts to get loose between adjustments you have a follower going bad, don't hesitate to make repairs as the bits coming out of the one going bad get caught under the wheel next to it or the one that's going bad and start damaging the cam. For prudence sake pull the rocker box at 150 hours and check them out.
 
Thanks for the heads up on the followers Dale, I'd already done the vent tube mod (as I do on all my dirt bikes) the drowning was more the rider than the bike...:)
 

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