starting - finally cured

arkley123 has had his FE501 for a while now and always found it a pig to start. last week he fitted the dutch clog decomp with the modified decomp spring (as per photo) had the "Taff's crescent mod" done and a new sprague bearing.

the bike has the original starter motor but does have the YTZ7S gel-cel battery. The bike starts first time! He may well get the R6 starter motor but on the 501 the decomp resistance is low enough not to worry about it!

i think we've finally licked it lads!

regards

Taffy

RE: Re: starting - finally cured

well of course now i can call myself an officianado of 1997 todate!!!! (only joking!) but basically the dutch clog decompm is shorter. now if you have a cam with a broad central shoulder so that it is wider than an alloy sprocket: you will need to machine about 3mm off.

if you have a cam that is slim there and only sticks out about 0.25 - 0.5 past the sprocket then its a straight fit. i've done 5 of them from 01 or 02 and this was the first one with the old broad shoulder on the cam.

2 minute job on the lathe!

anyway, i can't do photos as you know so if someone cares to show the front face of the cam with sprocket on at a slight angle we will see the boss i'm on about. the shoulder the sprocket actually mounts on.

regards

Taffy

i thought i'd answered that above. the alloy sprocket was up to 2001. after that it was steel sprocket with the narrower shoulder.

the decomp pokes through a hole to reach the cam lobe. the shoulder used to be broad and so the decomp had a long reach arm. then with the steel sprocket the shoulder was narrowed and a shorter decomp arm was needed.

now if you put this short reach arm on an old camshaft - it's short! the decomp lobe would only just reach the edge of the lobe and the CFB soon chipped the corner off.

i really hope thats clear. maybe you need to go and look at some photos and come back and read again.

i'll send some photos to eric again and maybe he'll host them once again for you.

good luck

Taffy

well i can't find a code for it like you usually get at the end of the part code?

i've just opened the '04. '06 and '07 parts books and there is no date for them but for everything else of course there is!

Ok, hair if you are reading this? thank eric, and study the photos. in the first you'll see that the far cam has a silver shoulder of thick metal showing through. the nearer assembly has a shoulder of 10 thou/quarter mill.

the second is an overhead view of the arm reaching through. that photo is of the old set up so as you can imagine, the shorter arm would barely get into the exhaust cam lobe.

the third photo shows the shorter arm reach. try and imagine buster douglas and mike tyson!

regards

Taffy

i have been given the opportunity to get someone's bike starting first time, its a 650 '02 and i said that i would do the lot to it. no holds barred!

first things first i went for all the kickstart stuff. this particular bike for some reason has a habit of the kickstart 'keyhole' seizing in position. bastard!

1) so i welded a blob on the end and that meant more of the 'keyhole stuck out the back of the gear and sat on the sledge.

2) i did the 'Taff's crescent mod' which can be seen in the doc and my gallery

electric start
3) i shortened the spragues spring and located the circlip correctly into the cprague which then upon fitting still clips into the housing for proper location - something often missed

having tried to start the bike i noticed the kickstart free again so it was cover off and get to the kickstart where i polished up the 'keyhole' again but also did:

4) the starter freewheel. having measured the torque at which my wrench clicked it was just 5LB - same as sparks, so having called sparks and been told i was a 'southern jessie', i put more ooomph into it and undid the very, very tight nut. having cleaned it up i found a shim and rebuilt it. torque limit wasn't actually found, i just went for 20LB and left it. like sparks i fitted a 0.020" (0.5mm) shim. before you pull it apart i can tell you that the most difficult part is that the ID must be 11 (eleven) mm.

5) a yamaha R6 starter motor has been purchased lately and was fitted. it needed two drill holes and shimming up the correct amount so that it was supported correctly. 8,5mm of spacers were required EXACTLY!

engine
the engine was fitted with the;
6) dutch clog decomp about a month ago and unfortunately the spring does bind slightly like loonybergs!

7) all the decomp cables are removed and everything that goes with them to leave a nice uncluttered look.

8) tappets set and valve timing (especially the valve timing!)

ignition
9) the genuine TDC was found using the dead stop method and yep! sure enough, the true TDC was equadistant to the right of the gap of the first two lines when viewed at 12 'o clock on the face of the flywheel. using a strobe TDC went from a line slightly to the left of the centre in the viewing hole to extreme right and the full advance came down from 47d BTDC to 33d BTDC. static advance at idle was 3d BTDC.

10) a denso IXU24 was fitted a month ago

carburation
10) i fitted a new atomiser and needle regardless - due to wear

11) i fitted a 40 choke jet as discussed earlier this week (see loonyberg for an opinion)

12) idle was later set, as was the fuel screw to suit.

what i didn't do:
electrical
13) it already had a YTZ7s battery fitted.

mechanical
14) checking for tuliped valves (done one month ago)

THE RESULT!
that R6 starter is something else! the engine flew over and i did something i've never done before on a husaberg: i fed it some throttle, caught the engine and she went!

bike runs beautifully. nice to have done the job properly!

regards

Taffy

defo a big difference.

i have one here still.

one thing i needed to add is that i had to kick the bike hard. anything less than full speed and it didn't catch. battery was relatively flat though. when charged it was far better. i noticed that yours suffered none of this which tell me that spark's stators spark earlier and at lower revs.

are you getting the lump of a decomp not working or is it just geberally being a "650" and bloody heavy?

talk later

regards

Taffy

and you need a spacer before you think you can get it for X just have a look at my price please?

IT'S KNOWN AS THE 'BEEFY' STARTER ON MY WEB SHOP.

Taffy

Tame thy beast. keep it for sure!