FC470 Bummer

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brucifer

brucifer

Joined
Jun 5, 2009
Messages
199
Location
Eureka CA
Hey guys, as you may know I just picked up an '02 FC470. I bought this bike over the phone and was told it ran but was making a clattering sound. It was delivered Wednesday night but I only tried starting it this morning. Nothing. Not even a fart or backfire. Decided to pull the plug and check for spark. Nothing. :x I took the plug and checked it on my XR650R and it sparked no problem. The stator has evidently been changed because the wiring under the tank has been spliced into and there appears to be two extra yellow wires going nowhere from it. Charging circuit maybe?
Also, I got to looking around at the engine really close and much to my dismay, the right hand maincase is cracked at the swingarm pivot. :cry:
Oh well. Looks like I REALLY have my work cut out for me!
I'll post some pics of this thing later.

Sorry mods, I really didn't know where to post this, so if it's wrong please move it. Thanks.

Bruce
 
The 2 yellow wires are for the lighting coil I believe. Yes the FC's came with a lighting coil.
The case is a common problem and can most likely be welded by a competant welder.

Good luck!!
 
Thanks for the luck berger, I'm gonna need it. lol
Here's a couple sunlit glaring pics. I'll take more when I begin the teardown.

husabergetc003.jpg
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husabergetc002.jpg
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berger said:
The 2 yellow wires are for the lighting coil I believe. Yes the FC's came with a lighting coil.
The case is a common problem and can most likely be welded by a competant welder.

Good luck!!
Click to expand...

What causes that crack? Bottomin' out, jumping are just a flaw?

Daniel
 
danielsfc501 said:
berger said:
The 2 yellow wires are for the lighting coil I believe. Yes the FC's came with a lighting coil.
The case is a common problem and can most likely be welded by a competant welder.

Good luck!!
Click to expand...

What causes that crack? Bottomin' out, jumping are just a flaw?

Daniel
Click to expand...
A combination of a weak spot in the casting and bottoming out. A siezed swingarm bolt will do it too. You usually only see it on 01's and early 02's.
 
i was going to say ken, the '02 had strengthened cases there, i think it's that old story of "a few very early '02s might have had the earlier cases to clear the stock"! otherwise i think it's fair to say it was just an '01 problem. and brucifer, you might think of a set of '02 or '03 cases but i'm afraid they'll be rare coz owners were running con rod alley and they are much sought after!

regards

Taffy
 
Probably better off fixing what you have. On the other hand, a new piston and ring set is well over $200.
 
Yeah, you're right. Thanks berger.
Well, I checked the resistance in the stator and naturally it's not within spec. Checked the valves and they were all too tight. Pulled the rocker cover to eyeball the valve train. It has the alloy cam sprocket (in good shape). Cam chain is tight. Rocker arms and rollers look to be in good shape. The auto decomp looks good and functions well. The cam, not so much. The intake lobe is going away. Pitting and starting to groove.
That's it for now.
 
check those inlets for tuliping!!!

also, if the tappets are tight and the cam is going south then i can't see how those little CFBs have survived. ok they may but i would knock the pins out 1/2 way and look for a dull grey look or spalling underneath.

agree with ken, weld these cases. you defo have an'01 or an early '02 engine because of that alloy sprocket.

regards

Taffy
 
Thanks Taffy. I'm going to replace everything with the upgraded parts anyway, whether they look good or not. :wink:

Here's a pic of the stator connector. Does it look correct for my bike? The reason I ask is because the one large plastic connector has been spliced to the wires. The coil assy. has that style connector.


statorconnector.jpg
[/img]
 
Sure thing, Taffy.

statorandcoil003.jpg
[/img]

One of the coil. The connector has been spliced here too.

statorandcoil004.jpg
[/img]
 
my mistake ok, you do have an original stator, you have a 6 wire stator. these charge the battery or run lights as well as run the ignition, however, your bikes wiring probably for just the ignition to be run so that makes the blue and two yellow wires redundant.

i need a photo of the flywheel at the 3/4 angle or side on as well please?

regards

taffy
 
I think what taffy is looking for is cracking or delamination of the flywheel magnets. If indeed they are cracked or delaminated you may want to replace the flywheel as well. Unfortunately I think you can only buy them as an assembly with the stator.
I'm sure someone will set me straight if I'm wrong.
 
Ahhh poop... Well, hopefully my flywheel is OK, although it doesn't look that great.
 
brucifer

you have a deep flywheel to suit the 6-wire stator. so they match. it does look like it's falling apart. if i recall the flywheel is also a SEM unit? i don't think steve (sparks) re -pts flywheels?

i have a 3 wire flywheel and ignition here so if you need to exchange then have a word here. or stick to the 6 -wire and wide flywheel (seems little point unless you're fitting lights).

regards

Taffy

regards

Taffy
 
OK Taffy, I'll keep that in mind. It might be kinda cool to stay with this set up to have the option of running lights later on if I choose. But, it IS a motocross bike after all and probably would be pointless to install lights. I already have them on my XRs. :wink:
 
Older Bike Parts Interchange

Do any of you know if the stator/flywheel from the earlier engines will fit my bike? Specifically '96 FC501 or '98 FE600. A couple of parts bikes came up for sale here locally.
Sorry for the questions guys. My apologies if this has been covered elsewhere.

Bruce
 

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