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Enduro Engine 4 stroke (including EFI & Exhaust) 4 stroke engine, EFI, and exhaust discussion


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  #1  
Old 08-26-2016, 01:53 AM
Tafka Tafka is offline
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Default 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?


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  #2  
Old 10-17-2016, 12:43 AM
Tafka Tafka is offline
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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....
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Old 10-24-2016, 05:39 AM
Tafka Tafka is offline
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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???
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Old 12-17-2016, 10:38 PM
mikethebike1127 mikethebike1127 is offline
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Have you checked the fuel tank breather??? Might be partially blocked causing a vacuum in the tank!!
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Old 12-31-2016, 09:02 AM
Tafka Tafka is offline
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No issues with the breather
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Old 01-01-2017, 05:25 PM
Nosedive Nosedive is offline
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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.
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Old 01-02-2017, 12:30 AM
Tafka Tafka is offline
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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.
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Old 01-02-2017, 07:33 AM
Nosedive Nosedive is offline
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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...
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Old 01-02-2017, 07:51 AM
Nosedive Nosedive is offline
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only in german:

from GG mounting instruction
Attached Files
File Type: pdf Zwischenablage01.pdf (128.8 KB, 46 views)
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Old 01-03-2017, 12:39 AM
Tafka Tafka is offline
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Quote:
Originally Posted by Nosedive View Post
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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