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Alternative engine???

Joined May 2005
8 Posts | 0+
Well, I realise this might be considered heresy around these parts :oops: but if you don't ask, etc etc.....

I have a 2002 FS650 which has only covered a (genuine) 1000 miles or so on road or tarmac track and is consequently in very good nick. However, it's an utter ***** to start, and even if it does start, it's completely unreliable (i.e. it'll start one day, think "ok, book the MOT for tomorrow" then it won't have a bar of it the following day). So, it lies at the back of the garage and never goes anywhere.

I've read the hard-start guide(s) til I'm blue in the face but I'm losing interest in flogging what may be the dead horse of reliability, which seems to leave me a few options:

- try and get it running half-reliably and sell it
- sell it as-is and take a hit on the price, or,

(and here's the oddball option):

- turn it into a project and fit a different engine

Has anyone done anything like this and what have you used and how did it turn out? Obviously the RH drive limits the simple options, although I guess anything can be done with enough time & effort. Are there any large 2-stroke possibilities (CR500)? I guess something from a KTM would fit but be pricey to source? A later Husa lump? Or something completely off the wall?

Anyway, flame away if you must, but am genuinely interested to hear of possibilities and options to keep me tucked away in the garage this winter.
 
I would say go for big KTM 2 stroke 500, 540 or 550 if you can find the engine. They are all right side sprocket and left side exhaust, kicker so that's 3 problems less.
I suggest you join ktmtalk.com and go to Oldie but Goldie subforum and try to find the engine, there are many of KTM big bore enthusiast that might just have what you are looking for sitting in their garage. One of them has 10 restored big bore KTM 2 strokes :D
 
So you can't even get the engine you have running, and you want to do an oddball engine swap?
This should be funny........
 
Funny guys.....here all week, are you? Try reading the original post *properly*. Oh, and don't give up your day jobs.

I wouldn't contemplate the task if I wasn't up to it. What I said was, I can't be arsed with repeatedly fettling a motor which immediately requires either a repeat, or different, task to keep it running in anything remotely approaching a useable fashion.
 
It would be much easier just to get the stator rewound so it works as it should. Strong spark will make it start.
Are you using the electric not-starter or kicking it?
There are simple reasons earlier Bergs are hard to start, simple reasons are simple to fix.
Give us the lowdown on your start drill and methods, you might just be doing it wrong.
 
My experience with this bike is once its set up properly to start well it shouldn't need constant fettling to keep it starting well. Are you sure you haven't missed something?
And my experience of engine swaps is they're a hell of a lot more hassle than fettling a Berg engine.
 
Im ditching the berg frame and keeping the sweeeeeet engine

we could go halves in an RMZ450 :D ill take the frame you can have the engine.
 
cappo
where are you from. these bikes can be made to start first time everytime. truth be told you should have been told by others here how to do it by now.

anyway, if you let us know where you're fromk please?

regards

Taffy
 
I understand your frustration. Now it sounds like even if you got the 'berg to go perfectly evey time you would still be waiting for the next problem.

Have had experience with a few Frankenbikes - fortunately not mine. While the concept sounds great you invariably end up having to make so many comprimises just the bloody thing to work that you end up feeling that too many things "don't quite fit properly". They end up killing your feelings toward the bike in the same way the original (unreliable?) engine did.

I'd recommend that rather than try to shoehorn a different engine into the 'berg frame, get a complete original bike of whatever powerplant you decide on, then turn your efforts to smaller modifications to make it your own. Even complete suspension replacement is probably easier to get to work well than an engine shoehorn.

Just my two bob worth.
 
Thanks Brad. You're right about the first paragraph, and I can very much see where you're coming from in the second para.....

I'm going to have a chat with Taffy about it and see where we go from there.
 
How about a KTM 640 engine?
If I remember correctly they have left hand kick start and right hand sprocket so that's one less headache. Having riden one a while back they are not as quick as a 650 berg but they do weigh @50kg more so it would feel far quicker in a berg frame, maintenance seems a lot less too.
 

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