Re-Intoducing My 2000 FE400!!!

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Bigbugberg

Joined
May 4, 2003
Messages
8
Location
USA
Good morning All!!! It has been a while since I've been on the forum. I've been doing some Adventure riding on my 2007 KTM 990A. Some nice long trips through Utah on the Piute trail, Death Valley, and local trips around Arizona. So all this fun I've having has left my poor old FE400 in a sorry state. Rather than buy another dirt bike, I plan to resurrect the 'Berg and reacquaint myself with a motorcycle weighing less than 600lbs!!!

I bought my FE400 way back in 1999 as a new 2000. I even still have the Husaberg backpack and fannypack that came wit the bike! The VIN is stamped "00003" so its a pretty early model for that year. The bike has been great except for a rear wheel bearing failure which ate my hub! Ouch! So in my quest to refurb the Berg I need a few parts because I'd like to plate the ride for Arizona.

Some things I'm looking for are a rear brake light switch, swingarm bearings, front wheel bearings, and the like. Perhaps a new cam as the stock as i remember is gouged around the seal.

In all of your collective wisdom, where might I find a good US source for older parts?

Humbly yours,
Bigbugberg
 
Welcome back Pete!!
Between BOSS and ebay you should have it covered.
 
The VIN is stamped "00003" so its a pretty early model for that year
Click to expand...
it's older brother is living well up the street in cottonwood (s/n 00002) :cheers:
ditto on BOSS for the parts.
on a different note: what ever happened to the dealer that opened in prescott valley a couple of years ago?
 
I think it was Star Cycles in Prescott Valley. Never went but they seemed to have pretty good prices on new KTMs.

Perhaps a <00010 reunion???? :mrgreen:
 
After realizing I wasn't going to ride the Berg on the street I removed the lights and the wiring harness. Now, with AZ State laws I decided to re-install the harness and wire in a brake light... All is good... at idle... Then I twisted the throttle... POP! There go the bulbs! Crap. AC volts as high as 40 everywhere on the harness!!! So ordered a voltage regulator. The regulator was $12 and has the center hole just like the stock unit. Sweet! It goes on tomorrow. Cross your fingers!

It is such a nice change working on this bike compared to my 990 Adventure!!! It is soooooooooooo much easier!
 
Ok, while taking the trusty steed apart I opted for some further modification... I removed the auto-decompression but kept the manual decomp. Rejetted and got a new air cleaner, adjusted ignition timing. Also removed the old speedo drive on the front axle and refreshed the fork oil.
Jetting now (1450 ft elev):
185 Main
38 Pilot
clip 2nd from top
All else stock.

Open the petcocks, kick 1, flub, kick 2 = VROOOM!!! I'm still amazed that this thing starts as easy as it does even with crappy old gas, sitting for an eternity, etc... Unbelievable. Still does the roll on wheelies just like I remember!!!

Test ride this weekend!
 
Gday BigBug,
I'm envious of the Utah riding. I was lucky enough to drive across Utah last year on a trip to Colorado then on to Vegas. Amazing country. How did the test ride go?
You sound like you know your way around bike mechanics. Just went riding over the weekend on my newly aquired 2000 Fe400. Great bike. Was all good until she decided she would n't start after having been very reliable firing first go most times.
Did basic checks - key, kill switch. fuel.. all good. Determined no spark to spark plug.
Any suggestions on where to look next? (look for a good auto electrician I suspect...)

Also - you mentioned you changed fork oil. That is a job I will need to do soon. Could you please provide advice on how to do it.

regards
T
 
Sounds like your problem is the SEM ignition going bad. Check with BOSS Offroad for a replacement. My '02 FE650 did the same thing except that it would occasionally produce a weak spark IF you kicked it hard and fast enough with the plug out of the cylinder. New ignition fixed it.
 
Oh, yeah, I replaced the stator years ago... Kick, and kick, and kick... No go...
I believe there is a stator troubleshooting guide to the stator. Berger suggested I send my old stator to some guy in Spain. He rewound it and it works great and that was 5 or 6 years ago. I have also found the plug wire can come loose from the coil. check the easy stuff first.
Fork oil, remove the top caps, remove the spring drain the oil (I also flush the fork with mineral spirits), drain again, add oil, then spring, then top cap, 30 mins per fork.

I took the FE400 out this weekend! Awesome! Some easy two-track with 4th gear wheelies everywhere!!! Sweet love, she is back in FORCE! HUSABERG FOUR STROKE FORCE! The new jetting had 6th just pull, and pull!!! I do however, flame out sometimes cracking the throttle from idle to open but the top rips!!! I've been thinking about getting a big orange 530 but after riding the 400 again, the 530 would be a handful!
 
Thanks for the advice.
Yep - have checked the plug cap - all good

Had the stator checked when purchasing the bike (month ago) and it was found to be fine - but doesn't mean it hasn't failed now of course.

I think I'll replace the spark plug as first step

T
 

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