Flashover FS650 2002

hofsviken · Dec 20, 2016

Hi!

I am struggling starting my Husaberg FS650 2002 model. The stator was broken, sent it to taffy for a rewind, messured and all within the specs. Still got no spark after the rewinded stator, so i started troublshooting thru the wiring.

When i just connect all the nessecery wires, red-black-green from the stator to the coil and black to earth from the coil. Got sparks now and then, sometimes there is and sometimes there is no spark at all. But i noticed that i could feel a weak shock in my hand when holding the sparkplug to ground.

I took off the black earth wire from the coil and the bike got spark every time! Talked to my dad and he told me it could be a flashover from the coil to earth.

Is the coil broken then? Have not had time to try start the engine with the earth wire removed from the coil, but will do tomorrow.

Appreciate all answers
Andreas

Rainerio · Dec 20, 2016

To rule out a bad ground/earth put a wire from coil to the motor. Bypassing frame

ned37 · Dec 21, 2016

you sure you didn't confuse grey wire for black?

hofsviken · Dec 21, 2016

Yes, did clean the wires very well to see the colors.

The problem now is that i need to kick the engine over real fast to get a spark. The engine needs to turn over waay faster than other engines i have been into. And i do not get a spark at every turnover. It won't spark if i connect the wires to the low/high ignition curve button, so maybe there is a short circut somewhere.

But my starter motor have no chance turning the engine so fast over that it will spark, even though i have a Yamaha R1 starter mounted and a car battery...

Getting tired of this bike now...

Is is much work to fit a auto decomp on this bike, 2002 FS650? Will new and better valve springs help the starting?

ned37 · Dec 21, 2016

i had an'02 fx650 that started quite well on the estart and was a 1-2 kick bike. but to get it to do that was a LOT of work. it required the yam starter ( i used the 600), and the steel cam sprocket (which required the cam be machined), and the later profile (dutch clog) autodecomp. the original autodecomp was a poor design that quickly wore out. i also had a keihin fcr carb which helped.
are you using the proper starting technic? a 650 does not like to start unless you start the kick at barely after tdc compression.

hofsviken · Dec 23, 2016

Thank you for answers

Have kicked it over a thousand times, just past tdc. I have tried different adjustment on the kickstarter decompression cable slack, from almost no decomp to more and more decompression. Used startgas to just hopefully hear it ignite, but with no luck.

Done the 1/6 turn on the valves, using the right TDC. Have adjusted the ignition just past the right mark on the flywheel. I have a rewinded SEM stator and have just the necessery wires connected to the ignition coil. Have a spark while kicking it over very fast, no spark using the electric starter with R1 starter motor. Think it has a good spark, but it is my first husaberg so i don't have any reference on how it should be. But i am now wondering if it could be the coil that is the problem.

I will try to jumpstart the bike as soon as the snow melt from the hill outside my garage.

And also another question, will the auto decomp device fit my bike, or do i need to buy the 08 model camshaft? And can someone give me an explanation of modifying the cam shoulder, maybe with a picture of where it should be machined?

Taffmeisters - Husaberg, KTM, Husqvarna, Gas Gas, dirt bikes - servicing, tuning, rebuilds, parts

ned37 · Dec 24, 2016

the '02 will have an aluminum cam sprocket with the old style autodecomp which is prob knackered.

the good autodecomp is shorter than the old because the steel sprocket has a recessed lip. so to get the newer decomp, about .060? needs to be removed from the cam to get rid of the gap, and the steel sprocket needs to be used.

OR...just find an '04 up cam with decomp and sprocket. (prob cheaper)

Taffy · Dec 24, 2016

the first half of the 2002's had alloy Ned but the second half had steel whist all the way through, the cams had the broad shoulder.

so this fella could be saving on his sprocket?

if it is on the road I would go for the later cam anyway. the old cam will be marked '53' on the end.

regards

Taffy

hofsviken · Dec 26, 2016

Okey! Thanks for nice answers and pictures

I have the opportunity to machine the cam down at work, so i have just ordered a new cam sprocket and also the auto decomp device.

And since i already will be working with the head, i ordered new valve stem seals, headgasket, modified cam chain tensioner blade, new cam chain and new rocker inspection gaskets. I think i will take the head off to clean and if necessary grind the valves and valves seat.

The bike was bought with unknown service history, so i will try to check all wear parts and clean everything down.

ned37 · Dec 26, 2016

sounds like you're on your way.
don't forget a new spring for the autodecomp.

hofsviken · Dec 29, 2016

Took off the head cover today, got a little disappointed when i saw the cams... Both exhuast and inlet has nasty pits and scratches on them, worst on the exhaust tho. The auto decomp shaft was just grinded round, and i think that made the exhuast side look bad. Took some pictures of it and i want your opinion if this is usable or not?

Taffy · Dec 29, 2016

not really sure what I am seeing there? you need to get in close for a photo and then crop it. anyway, I would NOT run my road bike on a 53 cam. sell it to me in p/ex against the 2004-2008 cam - the '08'. the 53 cam is a tractor cam - an MX cam. as long as your bike is on road that is not the right cam.

The ADC is always going to be wrong even if it wasn't worn away. you need the later upgraded ADC assembly with a strengthened spring.

Regards

Taffy

hofsviken · Dec 29, 2016

If you see the first picture, there is a lot of smaller pits on it and it feels rough. The one edge is a little flat also.

How much cheaper can i get the 08 cam if i send you this one to you?
I have already ordered a new 08 camshaft sprocket from you, so i will only need the camshaft.

hofsviken · Dec 29, 2016

And as you say, I have ordered the later auto decomp device with the new spring from you. So i am just waiting on the parts, but now i'm considering buying the 08 cam

Taffy · Dec 29, 2016

they are worth 30gbp but you pay the post!
some of those pits appear to be on the base circle. sorry fella but it isn't that clear I have to say!

Taffy

hofsviken · Dec 29, 2016

Tried to take some better pictures now.

Took off the head now, and that looks really good. Piston and cylinder all good i think

Taffy · Dec 30, 2016

the first photo of the 'nose' of the cam says 'toast'. finito. I - or you - could pay a company to 'clean it up'. basically, if you ever send anything too me then please chuck it in the bag too. one day, when I get to about 10 of them I will send them all off and have them 'cleaned'. but they are worth nothing to me to buy OK?

look very carefully at the CFB that sat astride that bad lobe. it might be 'going'.

try and think of Belgiun Pave and your meat and two veg on a bicycle riding along....I think you'll get the picture!

regards

Taffy

ned37 · Dec 30, 2016

try and think of Belgiun Pave and your meat and two veg on a bicycle riding along....I think you'll get the picture!

i know it's basically the same language.... but ?????

hofsviken · Dec 30, 2016

ned37 said:
i know it's basically the same language.... but ?????

Haha! Can't say i did get it ;D

But you managed to convince me, so I have bought the new 08 cam today

Started disassembly the valves from the head today, ready to install the new valve stem seals.

Taffy · Dec 31, 2016

Belgiun Pave is 'cobbled streets'. It is notorious in the Tour de France. the Tour de France is the world's most famouis bicycle race.

meat and two veg? no explanation required men!

taffy

Flashover FS650 2002

Help Support Husaberg:

hofsviken

Rainerio

ned37

Moderator

Attachments

hofsviken

ned37

Moderator

hofsviken

ned37

Moderator

Attachments

Taffy

hofsviken

ned37

Moderator

hofsviken

Attachments

Taffy

hofsviken

hofsviken

Taffy

hofsviken

Attachments

Taffy

ned37

Moderator

hofsviken

Taffy

Similar threads

Register CTA

Recent Discussions

Recent Discussions