1995 FE 501 Troubleshooting

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THELMINT

THELMINT

Joined
Jan 15, 2006
Messages
18
Location
USA TN
Hello everyone, I am new to the group, but I have visited often lately. This an an excellent web site. I have several problems. I purchased a basket case FE 501 from a local shop. I cannot get this thing started. I believe I have followed everything correctly. I have replaced rings. I have installed a Keihin carb temporarily until I get the Dellorto straightened out, I replaced all fuel lines, set valve clearances by the info I found here. The stator had one screw broken off in case and the other two loose, so I corrected that. I have a punch mark at TDC on compression stroke and another punch mark to the right of that which, when the flywheel is rotated CCW, I can insert a small pin through the hole and it lines up with the stator guide slot. I assume I have it timed close enough to start. I put the 38MM Keihin carb on, but I don't have the jet sizes with me. I have fire, and had enough fuel for the thing to backfire like a tank last night. I would appreciate if someone could break down how the fuel delivery system on these bikes works. I have been assuming that the vacuum from the motor moves the valve inside the box and allows fuel to move from the right to left side...? I also need someone to verify that I have the timing correct? The only info I have been using is from this web site, but the pictures for timing aren't like mine. I keep thinking this thing may be 180 out of time, but everything seems to line up correctly.
 
I think what you are talking about is a vacum operated pump wich lifts fuel from the right side of the tank to the left side, from memory if the tank is full this will have no effect on fuel getting to the carb, is it possible that the diaphram in the pump is stuffed giving you an air leak?
 
Thanks for the reply, the reed or diaphram was inop in the vacuum box. I had another and now everything seems to be working. I think I have finally got the needle valve and float level set in my Dellorto and I have reinstalled it. I will put my tank on and try again tomorrow.
 
thelmint: "I have a punch mark at TDC on compression stroke and another punch mark to the right of that which, when the flywheel is rotated CCW".

the crank turns clockwise if looking from the right/stator cover side. traditionally you would have a line at TDC and one BEFORE it which in this case is to the RIGHT of the TDC mark?

you got a good spark?

does the keihin have a choke? if still struggling, pull the carb then floatbowl and give us the choke jet size out the base! it'll be the one to the side of centre that is near the top (the PJ is sunk a long way on mine) and numbered somewhere near 60-80.

good luck.

regards

Taffy
 
Thanks Taffy, I think I finally got my Dellorto working correctly last night and I have reinstalled it. I have a K23 needle, I just set it to the highest mark to allow the needle to go lower. The main is 185, choke is 50 and 33 on the idle. I got the floats set to where when I blow in the fuel inlet, when air shuts off, hte arms are level with the face of bowl. The people I bought the bike from had been fooling with the carb, so I'm not sure if they put all the right parts back in or not. I do have spark, and everything seems to be timed o.k. but the only hint of life I got was a massive backfire. I hope to try and start it tonight...
 
She finally gave up tonight. this weekend I'll finally get to ride the 'berg. And no, I didn't have to tow it...
 
try and upgrade your internals to later spec stuff if you're feeling brave. the K51 and K35 needles are very good.

regards

Taffy
 
1996 FE 501 Starting Troubleshooting

Hi there,
I have a 1996 FE/FC 501 which I have just finished rebuilding from the ground up and upon trying to start it, appear to have come accross similar problems experienced by THELMINT below.

The bike has spark and fuel at the carborator but upon kicking with the choke on, will only give a Crack of a Backfire every few kicks.

The bike was previously a runner (before my time), so the only changes could be with my timing etc. on rebuilding the motor. I replaced the cam, cam follower bearings and cam chain. I installed the cam (non auto decompression) at TDC with the lobes down (cam sprocket allen head bolts horizontal in line with head/valve cover joint).

The carborator is as provided on the motor but I have stripped it and cleaned everything, the numbers being:

Main Jet - 185
Neddle Jet - 260
Neddle - K32 (on #3 clip)
Pilot Jet - 33
Start Jet - 50

I had the stator out, which was visually mint, would it help to rotate it (clockwise) to alter ignition timing? It is currently bolted in mid slot.

I appreciate these questions have been asked a million times before, but once again, any help/advice would be appreciated.

Thank you.

Cheers, Tony.
Auckland,
New Zealand.
 
it's very likely you don't need choke at all. you may get through a couple of plugs getting it running and then can clean them later. i would leave the ignition in the middle and get someone used to kickstarting singles to have a go. #

that #50 choke jet is big so you don't want more than one-kick wioth that before turning the bchoke off.

regards

Taffy
 
I have the same problem, I just bought a 96 501cc fe to replace my 501 fx motor do to bad rings and piston. I put the motor in and tried to start it but it just back fired, I assumed it was the timing. I tryed to time it but i get the same results every time. I could be doing it wrong but im not sure were to find the tdc on the motor. I need a visual aid or somthing to get me through this.
 
the problem you have is that while you keep trying different choke positions: on or off and then variable ignition timing points, the plug is fouling and the bike still won't start!

you need to lay any sooty plugs you get in a gas flame and burn off the excess fuel.

regards

Taffy
 
When I started timeing the engine I cleaned two plugs and checked the spark but after a few trys I didnt check the plugs.
So I took your advice and I checked the spark and there was nothing, I checked the wiring as far as I knew and couldnt figure out the problem. Im starting to think the coil is bad but not sure.
 
OK, wow never mind about the spark. I was being a ****** and it seems that i didnt kick start it good enough but a wire was loose and I re-attached it. It still wont run!!! the plugs are mint, I cleaned the carb, I even took the old cam shaft off the old 99 501 fx engine and put it on the fe engine to see if that would do anything. Im getting very impatient with this bike. It will back fire once in a while so could that mean that I have enough spark or could it be that my spark isnt enough? what are my options, I have another engine but the rings are bad but i can use the parts.
any answers would be great. I need to hit the trails sooon.
 
well it wants to start. the problem is: is it rich or lean and is it advanced or ******** when it comes to the ignition timing? the line wants to be either dead in the middle or slightly to the left of centre. jetting and choke wise they tend to get rich far too quickly so try one with and many without the choke. the plugs? I used to lay them on a gas cooker ring for 10 minutes and burn all the excess carbon off.

regards

Taffy
 
When you touch the spark plug when being kicked is it suppost to make your knuckles hurt or not? I touched my friends kx 500 spark plug and it felt like lightning shot into my arm but the husy isnt at all that powerful, could this be because the stroke difference or could my stator or cdi unit be bad.
 

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