Hey Husadudes!

jmumme · Nov 18, 2006

I haven't been on here for a while and just wanted to say HI.

I do have a question about when it's time to rebuild. I have noticed that the valves, after two years (desert racing), unfortunately needed adjustment (tight) so now I'm a little concerned about wear on my 04 - FE550. Same goes for my sons 02-FE400.

So, when is it time to rebuild? Who should do it, and what will it cost?
My motor has about 150 hours. Still runs great otherwise.
Does Lineweaver do rebuilds?

Thanks
John

Taffy · Nov 19, 2006

dale does everything and you won't hear us knock his work here. to be honest, anyone who is a true bike mechanic shoul d be able to rebuild the engines. whoever does it needs to go right through the FE400e from '02. that is exactly the year and model i have and built the doc around.

the list for the 400 is endless but i would do this.

replace ever shim, circlip, needle roller in the gearbox. check for wear in the gear selector drum.
replace every bearing in the engine bar the gears selector drum bearing.
update the tensioner with new camchain, modern blade and modify the tensioner.
new cam to go with those cam follower bearings. (get the right bearings)
pull the inlets and check for tulipping.
is the camwheel alloy? change to steel.
measure the piston. tolerances are in the owner's handbook.
new rings whatever happens there.
if you've had gear selsctioon problems you need to clean up or buy a new selector fork. if neutral is a sod then buy a new clutch drum - that'll cure that.

as for the 550. do the same checks really except that your engine has all the good stuff in it before you start.

regards

Taffy

jmumme · Nov 20, 2006

Hi Taffy,
Glad to see your still here. I was reading thru your updated doc. Which in great!
We have done some recent filing on the shift mechanism. My son likes to pound the shifter.
The only real issue with the bike (400) is starting. Should anything be changed out to help that? updated starter or ??
Were you playing with FCR carb? Is that a good thing?

Cheers
John

Taffy · Nov 20, 2006

there is a thread on modifying the dell orto. it's a LINK on the doc. then ask uncle joe what you don't follow from that. i have done a thread about nothing but 'choke' so try a search on that. it's a lot more technical than you give it credit for!

you could also do the "Taff crescent mod" (in the doc) to help with kicking.

go to a IXU24 nippondenso or the iridium equivelant from NGK. that'll help.

the FCR change is a lot of money but you could try it. there's a thread running right now for a 550 that won't run right and i've put my last std jetting specs up. my bike is too heavily modified now to bew relevant.

take a careful look at that gearbox and all the gears. look at the sharp corners in the selector drum....

i would even split the crank and give it a new big end. a machine shop will do this real easy!

regards

Taffy

jmumme · Nov 21, 2006

i would even split the crank and give it a new big end. a machine shop will do this real easy!

Aren't the cylinders coated? What size can I go up too?
John

Taffy · Nov 21, 2006

the 550 is maxed out at 100mm already. the 400? it will take the 95mm barrel from the 501, it'll take the 100mm barrel to form a 470.

i can't see how your son needs that unless he's some kind of super hero!

leave itbe. it's reliable it's quick. if you put the later cam or a lineaweaver cam in, you'll get a big hike in performance anyway. it gives them more torque and will a gear higher everywhere for the same acceleration.

regards

Taffy

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