Help! 09 FE450 Won't Start

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B

bkowal

Joined
Mar 20, 2012
Messages
75
Location
Ontario, Canada
An hour and a half into the 2 hour race, the Berg started coughing and sputtering, very simuliar to if it was running out of fuel. I managed to restart it a couple times and continue, but finally it refused to start again.
At the time, the lower part of the gas tank did have fuel in it, maybe a little more than 2 litres, so its not out of fuel. I did put more fuel in it to try again, but no go. It seems the bike wants to run, it will almost start. I can hear the fuel pump running. The bike is cooled down now, and still nothing. Also there are no FI codes showing.

BTW, this was my first DNF ever :cry: . My old Suzuki DRZ never let me down like this.

Any ideas where I should start?
 
Well, you haven't sold the DRZ yet.

Just kidding Brian. Hope you get it figured out. How was the course? I was planning on coming out for my first x/c. But ended up catering a wedding after a caterer backed out last Tuesday on a friends daughters wedding.
 
Kayeffess said:
Well, you haven't sold the DRZ yet.

Just kidding Brian. Hope you get it figured out. How was the course? I was planning on coming out for my first x/c. But ended up catering a wedding after a caterer backed out last Tuesday on a friends daughters wedding.
Click to expand...

I should have put the DRZ on the trailer as my backup-bike. Course was awesome, fast sections, tight sigle track sections with some tricky technical stuff, it was a tough course. Dust was crazy on the first lap.

But, bike was not overheating, I managed to keep moving fast enough to keep it cool.
 
And it continues..

I charged the battery, bike reluctantly starts but will accept no throttle without dying.
It will run for maybe 5 seconds before it stalls.
 
woody5248 said:
Check the fuel pump/fuel filter in the tank.
Click to expand...

Looked at it late last night. Filter on the pump looked perfect, no dirt to be found anywhere.
It has the aftermarket fuel pump and an inline filter.

I will dig deeper into the fuel system tonight.

Also checked the valves, they are spot on. Spark is nice and fat.
Battery connections are fine.

Bike would start and run for maybe 5 seconds, then die.
 
Kayeffess said:
Fuel contaminated with water? Did it happen after the creek/river crossings?
Click to expand...

Nope, course was dry and dusty, no big water crossings. There was a manure crossing, but none of that got in the tank.

I put new fuel in as well, no difference.

I will keep going tonight, still open to ideas!
 
I had a similar issue after I put the CA Cycleworks fuel pump on my 09 FE450. The bike ran fine for an entire ride. The next day I took it out to rinse it off in preperation for a race and it would start and run for a short time and then die. If I tried to give it any throttle it would cough and die immediately. Initially I though I had gotten water in somewhere and I was having an electrical problem. I even took off the spark plug cap and redid that connection thinking maybe it was intermittant. What it turned out being was a hole in the fuel line between the pump and the inline filter that I caused when installing the new pump. I guess it took some time for the hole to grow to the point where it was causing a problem. Most of the fuel coming from the pump was going back into the tank instead of through the filter and line to the injector.
 
Bike is running again. I went through the entire fuel system starting at the pump and working forward. Last stop was the fuel injector. I removed it, soaking it in cleaner for a few minutes and blew it out with compressed air while I actuated the injector using a small battery (see youtube video)

With the tank back on, hit the starter, and she fired up after a few cranks.
Must have been a dirty injector, everything else seemed perfect.

I'm glad it was nothing serious and I was able to fix it. It also gave me an excuse to check the valves while the bike was apart.
 

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