2003 FSE 450 issues...

[JBPT]

I recently bought a 2003 model Gas Gas FSE 450 Enduro which I converted to Motard and have had nothing but problems since. There have been 5 NRMA roadside assistance calls and countless visits to the bike shop up the road (not a Gas Gas dealer so pretty clueless as to what to do with the thing) all to no avail.

The latest issue is with the bike not starting. The last NRMA mechanic to have a look at it suggested that the fuel was coming on too rich, flooding the engine and that the battery was too weak to start the bike. My local bike shop reccomended I call a dyno guy which I did, he rang around and has not been able to find a suitable powercommander for the bike in Australia and has since told me to call the U.S distributors, Dynojet.

I have emailed Dynojet and am awaiting a reply r.e the Power Commander, has anyone heard of these problems before with this bike? I am completely lost and don't know wether to bin the thing or to keep plugging away in the hope of one day getting to ride this beast of a machine again.

Looking forward to hearing from you! Thanks, JBPT

[bergerhag]

Hey, and welcome to the forums and the Gasser community.
My first guess is that your fuel pump relay is going bad. Do a search on "fuel pump relay" on the forums and go from there.
If that is not your issue, browse through this subforum, it is packed with tips on what to do and how to diagnose it.

Check this thread too. http://www.gasgasrider.org/forum/showthread.php?t=7461

And do add your location to your profile. You'll never know, there might be a Gasgas EFI expert in your neigbourhood.

[iancp5]

You need to find a dealer with the kit to calibrate fuelling & TPC etc such as the Technoresearch VSDT stuff. You need the valve clearances to be good and you need a good battery. Then assuming no failures of key components such as fuel pumps (you can remove injector and see it firing by the way holding it together - careful with this not near a flame!) then it will start but not easily I'm afraid. They do start reliably but you have to find the technique and each can be different.

http://www.technoresearch.com/Produc...e_Features.htm

When everything is correct mine starts like this:

If lucky just press starter for a couple of 3 sec bursts without touching throttle

If unlucky, open throttle 1/4 - 1/2, press button and release throttle while cranking for 3 secs. If it fires still leave the starter cranking for a second or two.

[hillbilly]

bought same myself 2 months ago, then read forums and thought all was lost but worked through it all and now ok although kick start has no chance.
Dealer in uk gave me a lot of info as follows. Fit most powerful battery you can, strip out starter motor clean out all the crud, grooves on armature too, fitted new brushes as well. Mine still not turning over much better after this. Checked auto decompressor, all ok. Exhaust valve clearance too big, resulting in decomp not releasing compression. Change shim and turn over much improved. Read manual and noted that there is a button to press at back of throttle barrel. Push this in ( cracks open throttle slightly) don't touch throttle and now fires up every time within 2/3 attempts. Same when hot although finding it sometimes needs a touch of throttle. Only give mine short bursts on starter, don't crank over for ages and drain battery. Also had problems with intermittent fuel pump operation when turning on ignition which turned out to be fuel pump relay, loose connections when plugged into socket. I bent contacts in relay socket to enusre a tight fit on spades of relay when plugged in and now ok. Checked all wiring and found numerous sections with cracked insulation which could also cause intermittent problems so cut out and replaced all bad sections. Just completed first enduro and all ran well and pleased with feel of bike. First 4 stroke after years of 2T so still to get used to it. Hope this helps, don't give up!

[ricknaz]

Originally Posted by hillbilly

Exhaust valve clearance too big, resulting in decomp not releasing compression. Change shim and turn over much improved.

That's interesting. Was the clearance way out of spec and what did you reduce it to?

[markwoodlief]

http://www.shoraipower.com/

this battery solved all my problems.. oh and the secret little choke button behind the throttle..

[iancp5]

Originally Posted by markwoodlief

http://www.shoraipower.com/

this battery solved all my problems.. oh and the secret little choke button behind the throttle..

All this time .......................