FS650 n00b rebuild project

Howds! I've been posting here and there to ask for info and advice on that moneypit of a berg I bought a few months ago. Figured I'd better set up a single thread to record the epic journey!

So first of all, I bought a really cheap "easy to fix" non-runner FS650. Went to see the bike with my mechanic mate (neither of us any prior Berg experience) and we decided that worst case scenario we'd just sell it for parts and make the money back.

Bike looked like this when we brought it in (the better looking side):



Soon after we noticed that the engine didn't really fit the frame... few questions here and it turned out somebody stuck a 1999 engine in that 2004 frame - still not sure what cc the engine is! On top of that, the wire loom was butchered.
I managed to fall in love already, so rather than selling for parts as originally planned, I decided to try and source an engine. The rest would be easy, right?

Got this a couple months later:



It's a 2006 model, found it on the UK supermoto forum. It has a slipper clutch and looks breather-mod ready. Also got an FCR40 keihin (not 41).

Time passed, and finally got info that engine was in the frame, wohoo.
It then turned out the rest wouldn't be easy after all: the exhaust didn't match, wrong clutch lever/cable assembly,wrong throttle cables, and we were missing most electrics :furious:

I ended up buying the following:

- new CDI with CDI harness (that one hurt)
- used ignition coil
- new (but second hand) wire loom (found a random ad in Finland)
- used Reno exhaust, clutch cable/lever (in Poland)
- ignition barrel (thanks Taffy!)
- few nuts and bolts, engine spacer, throttle cables, fuel cap, and a few other small bits...
- coolant hoses
- + some more bits are on the way still.

Couple more months passed and we are at a stage where we can kinda fire up the engine. The carb is still off the bike though (and seems to be missing the ridiculously expensive hot start button!), some cables still don't have a home etc, and generally most of the bike is lying around the place.

Bike looks like this now:



Good news is I have some bits for sale. Anybody up for a working SEM ignition module or a rusty dellorto carb?

Ok, question time, if anybody survived reading through this:

1. See the cables coming out from the speedo? There is a pink one cut just by the white sleeve - any idea what the purpose of this one is, and why would somebody cut it?



2. There's a bit under the frame that looks like ground wires are supposed to be attached to it. Which ones do you have attached there?



3. what's the easiest option to set up the breather vent, if the one over cam chain has already been blocked off? I am also missing the Y piece breather that goes up to the frame.

Well, that's it, until the next episode!

Morning


you can remove the rear blank from the rocker cover I hope and buy the same tube as is already at the front. THEN get the forked oil trap and sponge and that will go straight to the frame. the racers got rid of one breather.

the 'earth carousel' is only for bikes up to 2003 with the SEM ignition. so it starting to look like you have a 2000-2003 chassis. the 10th digit of the frame number will be a zero, a one, a two or a three and that will tell you the year of the chassis.

so the electrics will have to come from a 2004+ with that engine and you'll simply need to be able to mount the coil. other than that I think you'll be OK?

I have a 2004 chassis here with the steeper headstock. it hasn't been registered but DCR gave me a letter of authenticity.

a carb that measures 40mm at the mouth is a 39mm because they go down 1mm through the venturi.

regards

Taffy

Thanks Taffy!

Checked the VIN number and it definitely has a 4 in 10th place, so a 2004 frame then. I'd assume somebody went through the trouble of attaching the 'earth carousel' to the frame when swapping the engines? Are we ok to pull it off, or is there still some cables that need to be connected in that spot?

We have most of the ectrics bought new, just looks like there's more cables than stuff that we can connect them to. Just need to put in more time...

Re the blanked vent, indeed the engine was bought from a racer, so that would make sense. Do you think it's better to return to stock setup, with the forked oil trap, or to go with what was done and just lead the one that is left open to a catch can? I've read all the vent mod threads here but I'd lie if I said they make sense to me

I'm a great believer in the forked twin oil breathers. the factory should have stuck with them. they just took the exit from the rocker from the wrong place!

the earth carousel can go. you should have had a pair of holes laying horizontally for your coil. however everything is do-able.

Taffy

Ok, we're missing something here, a bit clueless... is the boot the wrong size for that carb?

looks like a Dellorto and the boot is for a Keihnin. is that a Dellorto? If yes, then indeed that is the wrong boot.

Goose916 said:

looks like a Dellorto and the boot is for a Keihnin. is that a Dellorto? If yes, then indeed that is the wrong boot.

Click to expand...

It's actually a keihin, just not an FCR41, but a 40 from what I'm told, have a better pic somewhere... there we go. Am I missing the following: "Intake Funnel FCR/FCR-MX 02", part no 59031040200??

Looks like I'm also missing a hot start button (marked in red; )



And most likely rejetting needed... the spending never ends.

Ah, the clocks got connected today - only 10k km's done, mint! Question is how much is on the engine

hagetaka said:

It's actually a keihin, just not an FCR41, but a 40 from what I'm told, . . . .

And most likely rejetting needed... the spending never ends.

Click to expand...

Husaberg simply means "wooden boat with 2 wheels". A hole you can't stop throwing money into and a job for life!

there are two shapes of rubber boot. I guess that is all that is left to try but I have never seen this before.

is the engine leaning forwards? is it sitting on the frame?

Taffy

Taffy said:

there are two shapes of rubber boot. I guess that is all that is left to try but I have never seen this before.

is the engine leaning forwards? is it sitting on the frame?

Taffy

Click to expand...

As far as we can see the engine is mounted correctly, the mountings are ok. If you look where the choke button is in relation to the frame, it seems it's the right spot too. It's as if the carb is too short/missing a piece on the intake side - it even looks like the diameter of the boot is much larger than the carb's...

you need to check the distance between the top of the clutch cover to the headgasket OK?

if it is justv over 20mm you have a 450.
if it is about 40mm it is a 501/550
if it is about 55mm then it is a 650.

I think you have a 450. that rubber boot is the right one for a 650.

also, let us have another photo or two of the carb please?

regards

Taffy

i ran into the same problem putting a 39 keihin on my '00 400. i solved the boot matchup by digging in my box of car exhaust pieces until i found one that was a tight fit over the intake of the carb, glued it in place and cut to length.

Taffy: I'll try to get it measured, pretty sure the engine is a 650, but you never know!
Don't have more pics of the carb, but will try to source some.

Ned: yeah, we were thinking of either coming up with a creative solution, or just selling this and buying an FCR41... researching and considering now, will make up my mind at some point

i know a 650 would be happier with a 41

ned37 said:

i know a 650 would be happier with a 41

Click to expand...

That's what we're thinking, but really it boils down to how much I still have to spend on it
I'm at a point where I could just buy a decent FS650 for the money I spent on this, but where's the fun in that?

Taffy said:

you need to check the distance between the top of the clutch cover to the headgasket OK?

if it is justv over 20mm you have a 450.
if it is about 40mm it is a 501/550
if it is about 55mm then it is a 650.

I think you have a 450. that rubber boot is the right one for a 650.

also, let us have another photo or two of the carb please?

regards

Taffy

Click to expand...

Ok, the carb is a 39, measured. The engine is 650 (thankfully!). Think I'm going to ebay this carb off and get a 41.

hagetaka said:

I'm at a point where I could just buy a decent FS650 for the money I spent on this, but where's the fun in that?

Click to expand...

Indeed! Besides, you'd likely have to rebuild that "decent" 650 too!

Quick update:
Project has slowed down a bit, mainly due to lack of carb. Well, I picked up this today:



Trick, right? Now fingers crossed it actually fits

That carb has every aftermarket gizmo ever made. Hopefully it will do the trick.