1991 Husaberg FE350 with 600 motor

KendoIV · Aug 5, 2016

Alright, First time here, i dont know much about dirt bikes but i am very handy so bare with me. Back story, so a few weeks ago I Found this dirt bike being sold online for $600. I thought, what the hell so I bought it knowing that it will need some work because it wont start. I live in the Springfield area in Massachusetts.

What i know about the bike, 1991 FE 350 Husaberg Frame with a 1993 600 motor, 1999 Suspension and plastics tank and seat. Keihin FCR MX41 Carb with hot and cold choke. Rekluse centrifugal clutch, big gun exhaust and a trail tech vapor computer. Supposedly its automatic (no clutch lever). The top end has been rebuilt with new seals and the bottom end looks to have new seals as well but I have taken it apart yet.

The problems that I am having......It wont start and the kick start gets jammed and wont move. Let me elaborate on the kick start. 2 out of 3 kicks it gets jammed, almost like kicking a wall. If you put constant pressure on it, it will slowly push down and then i can get one or two more kicks in before it does it again. The first thing i did when i got home was to clean out the carb because the previous owner told me thats what it will need. It was pretty much spotless when i started opening it up. Put it back together and tried to start the bike again. Got it to back fire but thats it.

I cant find anyone for the life of me that will work on this bike. I have tinkered here and there but lack of knowledge on this bike and dirt bikes its preventing me from moving forward. If i cant find anyone soon, i am about to take it apart and just go with it. Recommendations? Anything would be appreciated about now.

When i get home tonight i will take pictures of everything if that would be helpful.

Kayeffess · Aug 5, 2016

Sounds like the bike is coming up on the compression stroke and the auto decompressor isn't working. A 600 can feel like a wall on compression. Wait till the big girl kicks back! Make sure you are kicking wearing boots.
Is there a small lever on the clutch perch on your bike? If so that would be a manual decomp lever. When the bike hits the wall, pull the small lever and just give it a slight push to get the bike past it. Then let the kicker back to the top and give it a mighty kick.
My starting ritual on my 01 is gas on, choke on, ignition off, pull the decomp and kick 10 times. Then bring it to tdc, push it over slightly, ignition on. Bring the kicker back to the top and give a huge kick.
Mine started this morning on the second kick with old gas and having sat for 10 months

Lots of resources on here. Maybe watch a Husaberg start video on YouTube. That might help too.
Good luck

ned37 · Aug 5, 2016

yeah, what he said. there is a proper technic to kicking a big 4 stroke single. follow his instructions to the letter.
biggest prob early (before '04) bergs had was the SEM stator crapping out. there are quite a few people who rewind them (Sparks did a few of mine). easy to tell a sparks rewind by the red blob covering the new coils.
but you indicate it has backfired, which indicates spark.
valve clearances are critical and must be done at tdc AFTER the intakes close. and are only settable if the rocker bearings aren't shot.
there is only one choke knob on your carb, the one with the small knob. the other is a hot start and you will prob never need it. make sure the idle is not set too high, and the pilot fuel screw under the front is at about 1 1/2 - 2 turns out.
only start it in neutral, but before starting, put it in gear and push it backwards and forwards to free up the clutch plates.
don't let it scare you when you get it running, respect it's authoritah.

KendoIV · Aug 5, 2016

Thank you for the replies. here are some pictures. (I think) the decompression lever you are speaking of isn't attached to anything on my handle bars. Is it the lever thats on the opposite side of the kick stand? In the 4th pictures right below the fuel filter? If so that cable doesn't go to anything aside from another lever that is attached to the front side of the top part of the engine.

At first i thought this had an auto start on it, but when i hit the start button, it was attached to the horn, never thought anything of it. I also couldnt find the auto start motor so i didnt even bother to think that he may have wired it wrong. Am i right to think that this doesn't have an auto start?

And i know the seat isn't on her, i was in the process of getting ready to take her apart again haha

Kayeffess · Aug 6, 2016

Yes that is a decomp actuated by the kicker. I can't tell you how they work as I removed mine. It doesn't look like it is attached properly at the head. I think you should prob remove the valve cover and have a look to see what it going on in there.

ned37 · Aug 6, 2016

i didn't like the kickstart actuated decomp. had more control over the handlebar type. my 98 600 had only the kickstart one and when the battery was weak, i would use it and it was a pain.
you could prob get a universal mount lever as long as you used the oem brackets. give us a closeup pic of the circled area so we can see what's there and what's not.
your engine does not have estart.
you can still start it without the decomp, but it's very tricky getting it just past tdc compression.

KendoIV · Aug 6, 2016

I'm sorry, i dont know why the photos keep uploading upside down.

ned37 · Aug 7, 2016

since your engine doesnt have the decomp cable stay down by the exhaust port (unless it's behind the black hose), you need to get the bracket that goes on the two allen screws on the rear rocker shaft area old part # 23004501 (couldn't find the new #) (see pic) and then use a 59002094000 cable from an '03 up. problem then, is that the upper barrel on this cable is small for a magura lever. my suggestion is to take the adjuster from the kicker cable and have a local shop make you a cable that will fit the cheapest small handlebar lever you can find.

Rainerio · Aug 7, 2016

Ned look at second upside down pic bracket already there. It looks like am getting 2 more Berg's 05 550 & 07 650 so I may be asking You some question Ned (old buddy pal chum)

KendoIV · Aug 7, 2016

Is this the stay down you are speaking of?

ned37 · Aug 7, 2016

yes. looks like all you need is a lever and cable. use the adjuster from the old cable on the new one.
but i would still try to start it by following Kayeffess's starting instructions. since you have a pumper carb, you don't need to kick it thru to prime it. just twist the throttle about 5 times. when it gets to tdc and it won't go any farther, push down hard with your hand, but gently so it only just goes past compression about an inch, then kicker all the way up and kick all the way thru. (don't have the kickstand down if you have one)
repeat as necessary, but don't overdo the throttle squirt.

ned37 · Aug 7, 2016

It look like am getting 2 more Berg's 05 550 & 07 650

my god, man, you're making me look sane

KendoIV · Aug 9, 2016

I also have another question, (Excuse me for my lack of terminology) but my gas tank, like i stated earlier, is from a 1999 Husaberg, which has two tanks basically, the left and right side. The right side has the gas port connected, but the left side is closed off. Im assuming this will be a problem since the gas on the right side will just sit there? or will the pressure pull the gas to the hose?

KendoIV · Aug 10, 2016

alright and another thing, Ive come to the conclusion im not getting a spark. Spark plug looks brand new, The stator has been replaced by the last owner. The batter that this guy installed on this bike is a Power-Sonic PS-1208 Link for anyone that wants to see. When i bought the bike, the lights worked fine and the horn worked. Im thinking this battery is either dead, or its not powerfull enough? PS-1208, PS-1208 Battery

Thoughts?

ned37 · Aug 10, 2016

don'tcha just love a half-finished project bike? (i know i do)
the fuel petcocks should join together in a tee and then to the carb. it's tough on a berg because the fuel inlet is so close to the pipe. berg's solution to routing on an fcr is to use a molded rubber "u" from the tee. any way you can get it done without burning the tubing is ok. most of the time, you just use the right side as the feed and use the left as a reserve.
sounds like it's time to test the stator. first thing is to id whether or not it is a stock sem stator, a rewind, or one of those aftermarket units that don't usually work. to see it properly, you need a flywheel puller (see pic on left) and also access to an ohm meter.

the battery has no function in running the engine. keeping it charged is another project for after you get it running.

KendoIV · Aug 10, 2016

Luckily when i bought the bike from the guy, he had all the parts from the other two bikes as well. So i have 2 other stators on top of the one that is installed.
The first one is the one that is installed and obviously the other two are what i have. I do have access to an ohm meter.

Kayeffess · Aug 10, 2016

First one is an electrex. Lots of opinions on these. Second one is a sems (all black). Third one with orange epoxy stuff is a sems that has been rewound by sparks here on the board.

KendoIV · Aug 10, 2016

So i tested all three of the stators. THe one that was installed on the bike was giving off some weird numbers that werent close to what i saw on a youtube video. https://www.youtube.com/watch?v=f8MmrXsEpjQ. The red one that someone on here rewound gave the closes numbers, I installed that one. I was able to get a spark. Sadly its to late now for me to try and start it but its progress so far.

ned37 · Aug 11, 2016

the red (sparks) is the one you want!

KendoIV · Sep 19, 2016

So i still cant seem to get a spark. Im thinking of replacing the entire electrical system with a new stator, spark plug harness and voltage regulator. Any recommendations as to where i can find all of these? Also is there a right and wrong one to get for any of these?

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