09 FE450. I'll never get it running again?

bikemechanic53 · Nov 14, 2012

I can't get my 09 FE450 to start.

I had to take the engine apart to replace a stripped countershaft. Put the engine back together. Started it and it ran fine. Sounded normal. Ran for 8 miles. Then died just like it was shut off. It restarted and I rode home.

I took it out a couple of days ago. It started and ran fine for about 3 minutes. Then died again. Would not restart.
It cranks but no firing at all.

I've checked:

Spark, appears good. It zaps when held against the engine.
Injector spritzes nicely on a piece of paper.
Valves in adjustment.
No injector error codes.

I haven't done a compression test, but, when cranking, the engine sounds like it's got normal compression.

I can get a fuel pressure tester. However, with the injector putting out some fuel, I'd expect the engine to at least fire some times or run rough.

Anyone know what I may be missing here? I'm sure it's something obvious.

DeeG · Nov 14, 2012

You didn't leave a rag in the air intake did you? That is the one thing you didn't mention - oxygen.

Cam chain tensioner? Maybe the timing is way off.

bikemechanic53 · Nov 14, 2012

No rags. But with me one never knows.

Tensioner is good. chain is tight. How could timing suddenly go far off when it ran fine only a few moments before? What could have broken?

Davo · Nov 14, 2012

I think DeeG means the Cam Timing is possibly out. As in did to have the piston at Top Dead Centre and the Cam Shaft Sprocket lined up with the dot on the head when you put the Cam Chain Back on?
Is the Fuel Injection Light working? You may be missing the codes if it is not.
Davo

bikemechanic53 · Nov 15, 2012

FI light flashes once while cranking. But no codes.

Cam timing should be right. I made sure the dots were lined up with piston on TDC when I put it back together. Anyway, would it have run fine for 10 miles before dying if timing was way off? I can't think of a scenario where this could happen.

I'm thinking something electrical. But if I have spark and FI, what electrical could cause it not to fire?

bkowal · Nov 15, 2012

bikemechanic53 said:
I can't get my 09 FE450 to start.

....

I can get a fuel pressure tester. However, with the injector putting out some fuel, I'd expect the engine to at least fire some times or run rough.

Anyone know what I may be missing here? I'm sure it's something obvious.

Check your fuel pressure. I had the same problem. Fuel pump was running, injector was squirting, but not enough pressure to get enough fuel to fire. A quick check is to spray some carb cleaner into the throttle body while cranking the engine. The extra "fuel" should be enough to get in going for a couple seconds. If it runs, then its a fuel problem, most likely the fuel pump.

bikemechanic53 · Nov 15, 2012

Thanks for the info. But it appears to be the spark plug wire! I knew it had to be something simple. The plug sparks fine when laid against the engine. But apparently does not when the plug and wire are in their normal position. Found this out by inserting a 'spark plug tester' between plug and wire. Started right up!

As my wife would say " if you can figure it out, then it's got to be something really simple".

fakesy · Nov 15, 2012

I was going to say check plug cap/wire as seen it happen with a Ktm & sounded the same,but thought no,I know jack really,so thought I would leave it to the pros,sorry mate next time I will give my jack 5hite knowledge a go

Davo · Nov 15, 2012

bikemechanic53 said:
Cam timing should be right. I made sure the dots were lined up with piston on TDC when I put it back together. Anyway, would it have run fine for 10 miles before dying if timing was way off?

Woops sorry, my mistake bikemechanic53 I missed this part in your original post:

bikemechanic53 said:
Started it and it ran fine. Sounded normal. Ran for 8 miles. Then died just like it was shut off. It restarted and I rode home.

09 FE450. I'll never get it running again?

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