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-   -   FSE 450 2005 idle misfire/stall when hot (http://www.gasgasrider.org/forum/showthread.php?t=21783)

Tafka 08-26-2016 01:53 AM

FSE 450 2005 idle misfire/stall when hot
 
Okay...i'm out of ideas.
I have a 2005 FSE450, last year rebuild, new crankshaft,piston,cylinder etc.
At one point, this year, in the middle of the forest, bike started to idle rough(misfire) and then stalls. Starts most of the time easy again and runs a little bit but then again, idle/low revs misfire and stalls if not given throttle.
High revs, everything OK. Some backfire when slowing down. Works fine when cold! but about 20-30min riding, engine getting hot, then the issues start.
Can't ride properly because stalls too often when riding slow forest trails. :(
Changed and adjusted TPS, new fuel pump, water temp. sensor, checked air temp sensor, fuel injector tested-good spray pattern, no leaks and flow rate ok.
Can't find any air leaks.
My next step would be change:
1) Ignition coil - i think i can find VW analogue (hell no i'm paying $200 GasGas "original" coil if i can get VW coil with $25)
2) Fuel pressure regulator? - PITA to find in Estonia :/
3) Pick-up coil? - does anyone know what should be the gap between pick-up coil and toothed wheel?

Any ideas?

Tafka 10-17-2016 12:43 AM

Okay progress so far.
Managed to replace original ignition coil with 2013 Honda CBR coil.
Got a brand new fuel pump assembly with fuel regulator for testing.
Put 2007 MAP to ECU, made things little bit better.
But still after all of this, when engine gets hot, at low revs and sometimes when taking off it feels like engine starves and then pulls nicely. Higer revs, everything fine.
I start to suspect maybe leaking valve(seat)?
Out of ideas.... :confused:

Tafka 10-24-2016 05:39 AM

One more remark....when bike starts to misbehave and i pull over for couple of minutes, let the bike idle, and then start to ride again, it works okay for sometime and then starts to act up again.....so something over heats but what??? :confused:

mikethebike1127 12-17-2016 10:38 PM

Have you checked the fuel tank breather??? Might be partially blocked causing a vacuum in the tank!!

Tafka 12-31-2016 09:02 AM

No issues with the breather :)

Nosedive 01-01-2017 05:25 PM

Hello,

I know these Issues actually from my 03 FSE.
Please check the valve clearance.
Ex is fine, even about 40k Kilometers after repair.
Can't measure both In-valves, cold 0, think they won't close when hot.

Tafka 01-02-2017 12:30 AM

Valve clearance is in spec. Just week ago had valves and valve seats grinded/cut and seated. Tought the valves might be leaking when hot but no change.

Nosedive 01-02-2017 07:33 AM

That's fine!
Helps getting closer to the causing part.
The hardware (Motor) is as new,
Software trimmed,
Sensors etc checked,
seems no EFI/fuel/intake problem.
Ignition. Coil is new, so are HV-cable and Plug?
Maybe a brandnew weak spark plug?
Let's think: what else heats up while running: pump relais,
rectifier/regulator,...next step...

Nosedive 01-02-2017 07:51 AM

1 Attachment(s)
only in german:

from GG mounting instruction

Tafka 01-03-2017 12:39 AM

Quote:

Originally Posted by Nosedive (Post 173714)
That's fine!
Helps getting closer to the causing part.
The hardware (Motor) is as new,
Software trimmed,
Sensors etc checked,
seems no EFI/fuel/intake problem.
Ignition. Coil is new, so are HV-cable and Plug?
Maybe a brandnew weak spark plug?
Let's think: what else heats up while running: pump relais,
rectifier/regulator,...next step...

Tried different spark plugs, still the same.
If relays would heat up, then the problem would be in whole rev range but my problem is only in the beginning....from idle to 3500-4000 rpm....after that its ok. But slipping clutch and holding revs so high in tricky stuff is pain in the a**.
I will try, at some point, to borrow a second injector....i checked my injector but in the test bench the injector doesn't get so hot...so maybe it's still the injector. Pretty much out of ideas....would like to get it running and then sell the bike :(


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