Problems with 1996 FC 501 Backfiring

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FlyinErb

Joined
Oct 14, 2008
Messages
6
Location
Atlanta
I have a 1996 FC501 and it was running fine until a couple of weeks ago. Now when I try to start it, it runs very rough with backfiring through the exhaust. I have taken apart the carb and cleaned it thoughly. I have also reset the valve clearances. I am not sure if it is a timing or a fuel issue.

Any ideas??
 
Airfilter Sparkplug

Clean the airfilter and the frame from oil and change the plug.
I changed the route for my breather tube to exit just above the chain now the plug is fine and the frame is clean from oil and moisture.
Take a look at the stator so you don`t have water in there and spray it with electronikspray.
It can be the exhaustvalves that are leaking and need an overhaul.
There you have some more reasons if the carb is clean.
Regards
Jampe
 
RE: Airfilter Sparkplug

Thanks for the reply. I have looked at the exhaust valves and they seem to be sealing just fine. I am have trouble finding a flywheel puller to look at the stator.

Thank you for any information to get me riding again.
 
Re: RE: Airfilter Sparkplug

FlyinErb said:
Thanks for the reply. I have looked at the exhaust valves and they seem to be sealing just fine. I am have trouble finding a flywheel puller to look at the stator.

Thank you for any information to get me riding again.
Click to expand...

Hi FlyinErb,

You have no need to remove the flywheel to have a look at the stator, just measure the resistance across Black and Red 1750 Ohms and Black and Green 23 Ohms.

Does the engine run rougher the hotter it gets, if so this could be a sign of the insulation failing on the ignition stator coils.

Regards

Sparks.
 
RE: Re: RE: Airfilter Sparkplug

sounds like the stator to me.

regards

Taffy
 
RE: Re: RE: Airfilter Sparkplug

I ran an ohm test and I received the following numbers. On the Black and Red wires I got .985 ohms. On the Black and Green wires I got .017 ohms. Do you know what this means, and how do I fix it?

Thanks again for all the help.

FlyinErb
 
RE: Re: RE: Airfilter Sparkplug

Check your stator screws, I had an older FE in the other week that had very loose screws holding the stator and gave a symptom of being either very lean or a leaking inlet manifold. Would start fine but then backfire BADLY when reved.
Best Regards
Sutto
 
RE: Re: RE: Airfilter Sparkplug

Is there a retro fit of a KTM that I can replace the stator with? I am have a terrible time trying to find a stator for this motor. Any kind of suggestions would be greatly appriciated.
 
Re: RE: Re: RE: Airfilter Sparkplug

FlyinErb said:
Is there a retro fit of a KTM that I can replace the stator with? I am have a terrible time trying to find a stator for this motor. Any kind of suggestions would be greatly appriciated.
Click to expand...

Hi Erb,

Not to sure which part of the world you live, but if you want it rewinding it's not a problem,
Just PM me if you require more details.

Regards

Sparks.
 
RE: Re: RE: Re: RE: Airfilter Sparkplug

I live in Georgia, U.S.A. How much would it cost to have rewound and how long will it take?
 
Re: RE: Re: RE: Re: RE: Airfilter Sparkplug

FlyinErb said:
I live in Georgia, U.S.A. How much would it cost to have rewound and how long will it take?
Click to expand...

Hi Erb,

Total cost will be 198.00 Euros. Total time back to the states is around two weeks give or takes a couple of days.
To save you a bit of time give Dan a call at Motoxotica he might have one of mine still in stock.

Regards

Sparks.
 
RE: Re: RE: Re: RE: Re: RE: Airfilter Sparkplug

I bought one from Motoxotica yesterday. I appriciate the advise and hope it solves the problem. I can't wait to get back on the 501!!!
 
There is another little thing people over look. Check and replace the plug cap. That can make a bike do what you described. Don`t over look that as its a fairly cheap fix but is over looked most of the time.
 
i know you said you cleaned the carb but make sure the pilot jet isn't clogged....also the float valve will stick closed when it sits for a period
 
Re: RE: Airfilter Sparkplug

sparks said:
FlyinErb said:
Thanks for the reply. I have looked at the exhaust valves and they seem to be sealing just fine. I am have trouble finding a flywheel puller to look at the stator.

Thank you for any information to get me riding again.
Click to expand...

Hi FlyinErb,

You have no need to remove the flywheel to have a look at the stator, just measure the resistance across Black and Red 1750 Ohms and Black and Green 23 Ohms.

Does the engine run rougher the hotter it gets, if so this could be a sign of the insulation failing on the ignition stator coils.

Regards

Sparks.
Click to expand...

I am having the same problem on my 1996 FE501. I checked the Ohms and the red-black is 1550 Ohms and the black-green read 35 Ohms. Is there anything else that I need to check right off? Any help would be great!


Just an update... I got it running right. It turns out that it was a lean pop. It had a large tear in the carb to intake boot that I couldn't see on the right side.
 

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