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fe501

Joined Nov 2009
49 Posts | 0+
Bellevue, Wa
OK guys this has been too long and costly and i need your knowledge on how to fix it, if you figure out the solution and it works i will paypal you some money for your time. 8O

So the story: :arrow:

i bought a 1999 fe501 from a friend friend that was moving and had this bike sitting in his back yard for quite a while and i know for a fact that the bike ran great because i saw it run 1/2 year back and trust the owner that was not an issue the issue was we could not get a spark so i still bought it and had it deliver to my house.

after going through out the bike cleaning all the contacts, wires everything and still could not get a spark so i look on line and contacted sparks from here he told me to test my stator well it turned out the stator was bad, so i sent it out to him to get rewound and i also sent him my cdi coil for him to test, got it back and he told me everything works great cdi and stator and of course (sparks did a great job on the stator).

So i got it back hooked it all up and after spending all that money, nothing no spark i was pretty pissed :angry: so i connected sparks again he confirm it all worked good when he was sending it out so i trusted him and thought maybe it got rattled around in shipping and broke, so after a couple months i found another one from a newer 650 (you may have seen my post) and you all agreed it should work and get a spark, well i got it today tried everything i could think of my ground is good stator is good.

so more money spent into this well i guess large paper wight and still nothing so im thinking my stator and coil is good but something else is wrong question is what WHAT WHAT!?!?!?! :? could it be the magnet around the stator??? throw your ideas at me maybe you will figure it out.
 
How do the magnets look on the flywheeel? That was what I was thinking while reading your post. They will delaminate. I have never heard of them losing magnetism, just basically coming apart.
You have changed your plug wire and cap? You are grounding the spark plug to the engine while kicking....right?
 
Disconnect the kill switch wire at the coil and try it.

As Berger suggested, test the plug cap, should be about 5 Kilo ohms.

How about the plug? Is it new or old.
 
^^ i have been cycling between a brand new plug and a old used one and nothing i have tried using new cables, yes i have been holding it to the frame and even lifted it a couple mm to see if it would just the gap i also have been doing this in a dark garage. how do you test a cap? and kill switch is unplugged keep it coming guys :cheers:

and i will post pics of the magnet asap not sure what to look for.
 
Ground the plug to the motor to be sure. I will use a jumper wire with two alligator clips, one to the motor and one to the plug electrode just to be sure. The flywheel magnets??
Come on man....fix this thing....I need the $$ :D
 
fe501 said:
^^ i have been cycling between a brand new plug and a old used one and nothing i have tried using new cables, yes i have been holding it to the frame and even lifted it a couple mm to see if it would just the gap i also have been doing this in a dark garage. how do you test a cap? and kill switch is unplugged keep it coming guys :cheers:

and i will post pics of the magnet asap not sure what to look for.
Click to expand...
you can take the plug cap off and sort the wire to the engine to see if it sparks, is the stator all the way into the flywheel, try some spacers behind it,
 
this should be an easy problem to solve.get a multimeter and measure resistances.make sure "ALL!!!" your connections&cables is OK according to wiring schema(look out for switches) by measuring them with multimeter.measure the output of your stator's both hi-voltage output and trigger signal.Step-by-step ensuring everything works well from the beginning.you should come into a conclusion then.don't use a plug.instead use the plug cable alone against a good ground.
 
My 2003 400 has a light switch on the left bar and when this is turned off - no spark, so it works like a kill switch and is in addition to a keyed ignition switch. I think it is wired this way so that you can't run without lights for legal reasons. So maybe check that yours is not like mine. It's a long shot but I'm totally comitted to the 50 bucks!
 
similar to what loz above is saying: i know my '98 fe400e (i don't know if yours is estart or not) had a thumb switch on the right along with the starter button that would kill the ignition but the starter still worked. the switch markings are confusing as to what is on and what is off. is yours like that?
 
No electric start (i wish) and not other switches the only electrical thing on my handle bars is the kill switch that is unplugged.
 
Is the ignition box under the tank grounded to the frame? I just had a similar problem with my Maico. Rust had corroded the area and it was not grounding where it bolted to the frame--looked good, but failed with the OHM meter.
 
TodColvin said:
Is the ignition box under the tank grounded to the frame? I just had a similar problem with my Maico. Rust had corroded the area and it was not grounding where it bolted to the frame--looked good, but failed with the OHM meter.
Click to expand...

Yes its under the frame, but the ground is good it read good with the meter.

i went back to the bike today as i bought a fluke volt alert pen and it detected a current (when i kicked) on the red wire from the stator all the way to the coil but not after, look like the current dies after the cdi on both of my cdi's which i know one is good and one sparks confirmed was good so i now know that a current does move all the way to the coil but im not sure if i should even be seeing anything after it.

im attaching pics of the magneto flywheel throw out your ideas guys.


P4130009.jpg

P4130008.jpg

P4130007.jpg

P4130006.jpg

P4130005.jpg
 
Disconnect the kill switch wire at the CDI (orange I think). That will take all the switches and/or shorted wires out of play. You can disconnect them all except the red-black-green.

Coastie
 
Anybody have more ideas??? heres the last thing i did.

i went back to the bike today as i bought a fluke volt alert pen and it detected a current (when i kicked) on the red wire from the stator all the way to the coil but not after, look like the current dies after the cdi on both of my cdi's which i know one is good and one sparks confirmed was good so i now know that a current does move all the way to the coil but im not sure if i should even be seeing anything after it?
 
I strongly suspect the kill switch or wiring for it. I don't understand the detail of how this works but the symptoms you have described suggest that all is fine as far as the coil and you have tried two coils and both don't work even though both are confirmed as good. So, just following the logic; there has to be something about the wiring that is stopping the coils from putting out a spark.
 
Kill switch is unplugged, what do you guys think about my magneto is it good looking?
 
flywheel looks much better than mine does... and my bike runs great. Mine is a 2002 FC550 with SEM and a sparks rewound stator.
 

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