Okay Joe, I’m going to chime in as well….. I’m a 63 year old gal and been following you a long while, I’ve enjoyed watching you along the way- I grew up in my dads engine shop- saying that because Dad always said, The engine needs “spark” “air” and “fuel” to run. You realized this bike had very weak spark! BAM!!! Your answer- wondering why you didn’t work on that before doing everything else that had nothing to do with spark? At any rate- love what you do, love seeing these bikes come back alive. Keep doing what you love but don’t over think 😊
I don't think I've shouted at a screen so much! You diagnosed a weak spark. Fuel was getting through because the plug was wet, also indicating a no-spark problem. So you then checked for wiring faults. Then you wanted to check the alternator/ignitor. Then you adjusted the timing, and it was downhill from there! You completely forgot about the weak spark and checked valve gaps, compression, valve lifters, carburetion, jet sizes, float hight... non of which would solve a weak spark which you had already discovered. Weak spark could be a failing coil. I'm only at 35min mark, so hopefully you'll find it. Enjoying your work. 👍
I messaged him after the first video. I had all the information he needed as i have and have had many of these bikes and i also know exactly where if he needed parts he could get them. He replied and never returned to the message. Well. Here he is. Just fixing the starter would have taken him 45 minutes. He is a good mechanic but he should stick to easy Japanese bikes. These bikes are for men.
Yes, I was saying to myself, "Come on, Joe, weak spark even in free air". It may be a no-spark under compression, even though that is eased with the lifters. I can't fault his dedication though, but he needed to stop completely and think. I would suggest he comes back to this one after a good while having some nice successes.
Brush your teeth in a up and down movement, 4 times per brush length... Tie your shoelaces with the right loop over the left loop, Microwave your steak for maximum time efficiency
100% weak spark. Get rid of those HOUSEHOLD wire nuts, solder those joints, check your COIL ground, double check OHM on the stator and STOP MESSING AROUND!! You KNOW what it is Joe!! That thing should be THROWING blue flames!! SPARK SPARK SPARK!!!
I used to ride old huskys and the best way I found to start left hand kick high compression bikes was to stand on a block and to bring bike to top of the stroke then kick hard I felt horrible watching you kick that old bike ....I am 50 and I love watching you repair old bikes have A great day from eatonville wa
I owned one of these, the stator is the problem, you have to get it rewired & it will start no problem. They will be running one minute, you will turn it off and they will not start again. The stator has packed it in. Late model ones has Japanese electrics which improved them greatly. I used to have a spare stator sitting on the shelf ready to go. Hope this helps.
@@Carboneye7 It's just the way I troubleshoot an intermittent. Before you start tracking down a ghost problem, fix any problem that you CAN see. Wire nuts are not made for motor vehicle connections. Like you say they may come in contact with moisture unlike when they are used in an inside setting.
@@oldguysoldbikes That's actually a very good call. My 2 Stroke KX wouldn't start after a very light ride one day. Never heard, felt or saw anything. My gut told me it was a weird, non-serious issue. Other people were going to extremes. Turned out to be an intermittent short in the wiring. Had I listened to other people, I would have been practically tearing the bike down. In the end, it was a minute of soldering. I spent more time waiting for the soldering iron to heat up than I did actually working on it.
That SEM ignition has always been a problem, Husqvarna used them and husaberg is just a Husqvarna after the engineers started their own company. Ditch the stock ignition for aftermarket and the bike will run like new. That's actually a great bike once the ignition is replaced. Common issues on all Husqvarna and Husabergs of those years. SEM ignition sucks, sometimes works, most time doesn't
Had a similar problem with a Husky. Coil ground! Looked good but after a good wire brushing on the frame and coil it would fire up first kick every time.
Completely agree! My buddy's XC had this same impossible to start issue, was a looked-good-but-was-bad ground connection. Re-do ALL the grounds as @coaterdave says, and you'll likely fix this. Also get rid of those wire nuts, they don't belong in a DC system nor on a vehicle. Never give up, never surrender!
You said it at least a dozen times "weak spark". When you have to turn out the lights to see a spark on the plug it's not good. You have compression and fuel so the only thing left is spark. I'm sure you'll figure it out but source a starter motor or the only thing you'll be riding is a wheelchair.
Your dumb summary (you have compression and fuel so the only thing left is spark) ignores many many aspects that make an engine run. Such as the right amount of fuel, camshaft timing, ignition timing for example. The fuel air spark story is way over simplified.
35:08 now your chasing your own tail by going back to fuel. The new plug is soaked in fuel. You don’t have a fuel issue. It’s coming down to that faint spark.
A few things to look at for weak spark, Check all your grounds, battery to frame,frame to engine, the coil and regulator /rectifier, maybe been mounted back over painted or rusted frame, kill switch wire maybe grounding out somewhere, bad coil lead to plug, plug cap cracked. pick up coil in stator not seated correctly.bad cable connectors, bad wires from the stator to connector, they sometimes disintegrate with heat and age, test your coil. good luck
SEM ignitions were a failure point and you cannot buy replacements.I have a 87 Husqvarna 510. Same issue. Very weak spark if any. Replaced with Vape ignition and now I have a very strong spark and the bike starts 2nd to 3rd kick. Left kickers are no joke!!! But when you can get a thumper to run. Lots of power...
2001 does not have SEM ignition. 1999 was last year Husaberg used them. Raced these for years. No issues ever with starting. First Ktm 520's used the exact same top end. He has no idea how to use the built in compression release. He will break the kick start gear if he keeps kicking against full compression. Used properly l could start mine with either foot. The bike works fine his issues likely stem from poor maintenance and a lack of understanding of the machine. Two failures in the time l raced these from 1996 to 2005. One was the previously mentioned SEM ignition on a 1999. Updated to the 2000 ignition and never had another issue. Second one was due to a case that got damaged in a cross country race and ran low on oil. Playing with timing without having the specs is foolish.
@@othgmark1 Yes its SEM it shows in the video its stamped SEM, i hade a Husaberg 550 2002 it hade sem. Ibelive they changed the ignition when they change to Kehin carb
@@othgmark1 I had a 2003 model which is pretty much exactly this bike and that definitely had the SEM ignition system on it as I had it blow out on me and had to source a replacement. 2004+ models switched to Kokusan.
The motor is a 470 which is the high performance moto version with 13 to 1 compression and will start better with race gas. The 400 and 501 were the Enduro motors. The starter is weak and battery small for the engine. I would replace the battery with a bigger CCA one and use the decompression lever to get it spinning easier with the starter. The FCR carb makes it start and run better.
I even saw a post about up sizing the main battery. And another about wiring a 2nd starter battery in series to 24v the starter Idk if it was a random post or not.
You can see where the previous owner was chasing his tail working on the spark problem, try removing the stator and insulating the wires that are up against the housing that have no insulation, or get a new stator.
It sure seems to be “leaking” spark. Test the plug wire, at the boot. I do not know how to do it, but I think when you measure the voltage coming through to the top of the spark plug, you will find that too much of the spark is LEAKING off before it gets to the spark plug. And why you must kick it over SO FAST to get ENOUGH spark that it fires. Alberta Jim
Could try the plug wire , they can corrode internally... try cutting it back at the boot end or replace it with another. Ohm out the coil... they fail over time.
This is a good example of a machine that can explain why many GenX dirt bike riders, myself included, stick with our 2 strokes. Starting some of the earlier "performance" oriented 4 strokes was a hassle on the best of days.
@@dylisaI remember those kick till Mondays. puking trying to start mine for a hour deep in the woods. It was also electric start but I never kept a hot battery
@@dylisa KTM were more or less Husabergs at one time. KTM bought them, took the knowledge and stole their slogan "Ready to race" before ending production..
Flow of this one was confusing. No spark detected with plug out. Next steps was to check timing and compression? Wouldnt you want to get a spark first?
one thing to try is if it has a light switch, turn lights off. if it doesn't have a switch then un plug headlight and tail light as they try to turn on when you kick it. if you have them disabled that will be more energy going to ignition while kicking.
I never thought there could come a bike that you can't fix and / or give up on it. It's sad to watch when such a positive calm person like you loses the spirit to continue. Just go for a walk with Vinnie and continue with a new project. All the best
@@keithwarrington2430I would say this is the best because he shows everything in dept. I'm an electrical engineer myself and I can tell exactly what the problem could be besides that I learned so much from this video
I agree with everyone. Its gotta be the stator. Have you pulled the flywheel to see if you spun the keyway? Another off the wall shot is the bike was rebuilt. Maybe the piston is backwards. Cut all the wires back, solder them together. Trim the plug boot for sure.
As someone who has owned one of these beasts, there is a VERY specific sequence to follow to get it to cold-start off the kicker. 1. Make sure the carb is clean, and you have spark. The stronger the spark, the better. Fuel on, choke plunger out. 2. Pull in the decompression lever. Kick the bike through about 5-6 times. This primes the circuits in the carburetor. 3. Kick through until you feel the piston coming up on the compression stroke. Pull the decompression lever, kick thru until you _just_ feel the engine go through TDC. 4. THIS IS THE MOST IMPORTANT STEP. Roll the throttle open all the way, hold it there for about a second, then release it. This puts a shot of fuel into the intake from the accelerator pump. 5. Get braced, and kick the bike over with EVERYTHING you've got. Don't touch the throttle all while kicking. If the bike doesn't fire, repeat steps 4 and 5. These bikes were pretty lean on the pilot jet, and the choke doesn't give it enough fuel to really fire over cold. So you're using the accelerator pump in the carb to shoot in some fuel.
My best guess is spark because I worked on a lt250r that would start randomly and then die. Spark was weak but there. I looked at the stator and the pickup coil was broken. A new stator and coil fixed it.
I used to have an old CZ motorcycle that was left hand kick that started very easily. Loved that bike. Back in early motocross days its was CZ Bultaco and early Suzuki
How about you put together a portable starter motor like they have in F1. Like a car starter with a fitting that will fit the shift gear/shaft. You could have a little stand too. Then you could have a 12 volt car battery, and hit a button and turn the engine over as much as you want.
Just roll start on a hill like the old flat track racers, they would strip any weight they could including kick starters or starter motors, and just roll start...
Get one of the 20$ china coil , cdi , 4 wires , mag style , or 12 volt ,you only need the trigger , if it dosent spark then , try to install some other trigger , weak spark get killed by compression . Kohler makes a spark checker that simulates what compression does ( jump a bigger gap), Great content ! Don't give up !
😂The ending, "if you can come start it you can have it". Man that got me😄. I could just picture a line of guys out the garage warming up there kicking leg with one moto X boot on😂. If and WHEN someone shows up to try you gotta get it on video. I have a feeling atleast a couple are going to hit you up.
Great video as always Joe, I am amazed by your persistence! I know all too well the feeling of wanting to throw a bike down a cliff! But you totally got this one, if you don't start it nobody can! You know much more than I do, but I'd just mention my feeling is that the weak spark issue you identified is the culprit. It is not uncommon for dying stators to spark outside of the cylinder but lose spark under compression. Your stator does not look very good, it seems to show signs of corrosion/humidity. Probably will start right up with a replacement stator. If that does not work, maybe check for the resistance of the electric cables: last winter I worked on a 1962 motobecane with weak spark not starting that two shops had not been able to fix, and found out it had a wire corroded internally (with no external signs of damage) making a very high resitance and eating the spark out...
I'd go with stator coil continuity and earth/resistance check first, if all is good go to the next electrical part in line like the ignition coil. As many say weak spark is the issue, not the timing. Hope you will find the culprit of the no spark issue!🤞🏻
Definitely need to put on a new stator and/or cdi box. Your values were lower than they should've been. If it's only sparking when it spins over fast that is definitely a stator or cdi box issue. I've had this similar issue on a few bikes i've worked on and the fix was a new stator and/or cdi box. Love your videos btw! Don't give up!
You got it started earlier when you bump started, since then you have messed with the stator, maybe try rolling it back to where it was and see if it starts easily when you bump start it, if it does then try adjusting it the other way. I am sure it's very finicky with the stator alignment, and I would also question those cams a bit too.
If your spark is weak, it will spark when you have the plug out, but the compression will blow the spark out, could be why you get it to run occasionally as it will go when it hits mix sweet spot. Go over the wiring properly get rid of all the bad connections and re-check your readings on the stator and coil. Electrical work isnt a dark art if it looks right it tends to work right if it looks shit it is shit.
Dont give up !!!! You recognised it has weak spark but failed to fully check the sytem.... go to coil... test coil.... Dont underestimate your ability...
I’m still watching this episode and I haven’t seen the conclusion yet. Usually you are very methodical in your process. This episode, however, you proved to yourself that you lost spark, then you chased timing, and valve adjustment and compression?? None of those will create or negate spark. I’m still waiting to see you check the kill switch and the spark plug lead.
Change the damn coil dude its broken down gives some spark but not enough. If you would ohm test your stator you would know immediately if the stator was bad. dont know why you did all that other stuff and waste time if you had weak spark to begin with
You are very Talented and very strong about getting the work done. Here is what I know for sure, this is a good bike, that is hard to start, if you don’t know how to start it.
I had one of these new in 2004. It was 100% reliable and started immediatley on the button. Very light, fast and just floated over the roughest ground. In 2004 they were the ultimate dirt bike, but yours seems to have had 20 years of neglect, so perhaps unfair to call it The Worst Motorcycle Ever Made. The 650 version is a beast of thing! All the best Paul.
Just a thought, When you had it partially firing on every kick maybe go the other way with the timing as it clearly got worse altering it the right way ;)
I think your problem is weak spark. When you were kicking it over (unsuccessfully), the taillight came on. Somehow you need more juice to the plug. Also agree: solder the wires together and get rid of those twist connectors. Finally, avoid all four strokes that kick start on the left.
You're starting it cold, once it runs, it warms up to some degree, then dies and won't restart. Like others have stated, perhaps a bad stator, but what about those janky wire nut connections? Something heats up just enough to cause an open? I would touch every electrical connection. Remove, thoroughly clean, and reattach. Connectors, ground points, all ignition related connections, everything. Just because it 'looks perfect', doesn't mean it always is. Check all fuse connections, as well as switch contact points, cleaning, and dielectric grease, as needed.
Yes, and judging by the corrosion on the frame and head studs, the first place to 'start' (heh heh) is to sterilize and re-do EVERY GROUND. No exceptions! And then ditch the wire nuts, at least replace them with proper connectors. Win!
Noooooo. Don't give up! There are a bunch of how to videos online showing you the start procedure. Don't you have a spare motor? Grab the stator off that. Maybe try disconnecting all lights and electronics not part of the ignition circuit. The stator should have two separate windings (one for ignition and one for lights). Lights shouldn't run off the ignition circuit. Once it's flooded you have to wait it out. If it doesn't fire after a couple kicks try again later.
Just buy a Horsepower Ignition System for it if they make them for this model. For about $250 you’ll have and brand new ignition system that works perfectly.
Back in the day, I had a 2000 FC501. It was really fast in a straight line and could do endless wheelies! Unfortunately, had the same problem with it not starting and found out that it was the stator. 6 months later and 2 more stator replacements AND multiple fork seals, I’d had enough and just traded it for a Honda CR250 and left the European bikes alone.
Welcome to my world. Once you think you've completed a job, POW needs a little more tinkering. You have the patience and knowledge, mostly the patience. Cute little battery
you have a weak stater so when you kick it faster it generate more energy some of them came with a battery, the battery helps increasing the voltage and you get more spark. Look at the brake light in the video. when you have a weak stater take the bulb out so that it does not steal power from the circuit. regardless of timing spark is spark weather out or not of specs. but you should put all marks to align so that you can get it running easier when you solve your stater issue. finally check for a good ground.
@@royhenson3379 i live in sunny south florida he is not just around the corner. just helpful hints. This guy is great and i have learned more about his video than anyone out there on you tube. but i did run into a similar issue with a bike i was restoring and was not able to find the stater anytime soon. But what i did in order to test the motor until i can get the stater was to find a spark plug with a lower resistor value so i can get more spark, you loose alot thru the plug wire as well. sometimes its a simple ground issue.
4 Srokes suck!!! I've rebuilt my 2000 CR250 3 times since I bought it Brand new. J&N innovations Suspension the bike has literally never let me down I'm 57 and still race OTHG on the GFI / AMP circuit and refuse to buy a 4 stroke. Love your videos keep em comin.
Happend to me, I became a after ride procedure to spray the stator down with some WD40. Also the kill-switch needed WD40 after washing that bike. Man was it a PITA..
The starter relay needs to be connected to the battery, it also feeds power to the ignition box. That's most likely why you're getting weak spark unless you kick it as fast as possible. Because it's having to charge the cap off of the kick instead of the battery feeding the ignition.
I have noticed he does tend to do a lot of unnecessary kicking on the bikes he works on. After a dozen kicks quit till you find an issue. Like every one is saying it’s not going to start with a weak spark!
*(Look up TCI VS CDI)* Well... I know some Models of Bikes Don't like to Start with kick Start when battery is "Stone dead" TCI System. As in Low to no Spark. And When Battery is Low They don't like to run right. Replace battery and they are Good. or Check for spark again with the Jumpers on her. You Charged the battery up a slight amount... So this is why it worked for a bit. "TCI takes a good amount more power from the charging system to power the spark plug in order to provide a longer and more powerful spark" I see you got a new Battery , i did not Watch the Full video.(Yet) i am sure you talked about this already.,
just watched the video in full , makes sense why it will fire a little , you are kicking and charging the battery until the TCI will "boot" then it fires , the battery cannot hold a charge / will not charge. the TCI needs at least 8V in the battery to keep the bike running right. always fun to change a battery when half the bike needs to come apart to swap it LOL!!!! Without the battery inplace. you can also do damage to the TCI system. Very important to keep the battery charged and not try to start with it off.
My thoughts exactly. Put that new battery in and test the spark, sometimes the old bikes need a charged battery to produce a solid spark. Once it is running for a little while, this will not be a problem, but cold starts might need that battery.
It is quite possible that the weak spark is caused by an ignition component on the way to complete failure. A manual showing the required range of ohm and voltage readings of the various components would have been a great help.
Many Bikes have inherent Problems, understand those Problems, you can find solutions. As a matter of fact, a good master of his craft can make solutions! Good Luck!
@@kiwiingenuity1677 I had an 83 KTM 495 when I was 16. That thing would backfire during a kick and damn near shoot me over the bars. These puppies these days know nothing about compression. LOL
the only thing that could be bad is the stator i cant think of anything else .. man you went trought the whole bike 😅 i admire the patience you have to work on this if it was me i would drive this thing into a lake and never look back 😂😂😂
Joe solder them wires on that stator and get rid of those wire nuts for starters. Do a voltage check on that stator and a ohm check and make sure your in spec then check the voltage regulator...
i might be wrong, but how does "kicking harder" make stronger spark if there is battery connected. Generated electricity from rotor goes to battery and from battery to coil to plug to generate spark. So my guess is something between battery and plug, maybe a ignition coil?
This reminded me a little of that Kids In The Hall episode where the car won't start. So they wash the windshield and spray paint it red to try to get it to start lol. Joe seems like a genius, far too sharp to not follow the spark. Hey, content creators have to create content.
Every time I watch one of your videos and my wife hears it in the background she says of watching the kicking king guy again. You must have a leg of steel.
2vintage i have owned 3 husaberg 2 of the same models as you`re 1 and they have all been a total pain in the butts to start even the 1 with a full rebuild,, all left hand kick start bikes are a pain,, but there is a kit you can get for $400 that turns them into electric starts and work great its what i did to all of mine and started fine after doing it..
By the way, I really love your videos. I wasn’t being sarcastic. I admire your patience and method and I also respect that you published this video too. That’s cool to see. Because my threshold for frustration is so low I rely on folks like you. My son and I watch your videos a lot. 🤘
Makes no sense if there's no spark. New ignition cables and coil at first, then stator/cdi. Maybe aftermarket ignition stuff to get spark. Running Husas are real fun, don't let it down :)
I had one of these a long time ago, it taught me patience. I wouldn't trust any twists in the wires, can mess with the voltage/ohms. I would try to get rid of those wire nuts.
That moment when you say to yourself “why the hell did I buy this thing”. I’m sure we’ve all had at least one of those moments, in addition to “I never learn” when you do it again!
Joe, I commend you for being so persistent on this bike. I think most agree its some type of spark issue, but the problem is getting parts, if you do need a stator, coil, or rectifier. I think the "Joe Give Away If you can Start it" saves future knee surgery! Thanks for your great content.
I guess you didn’t read my comment on your last Husaberg video. I spent a full year understanding the exact same issue you have here. The root cause is the marginal SEM ignition. Even when new they were troublesome. Add 20 years and undoubtedly a few minor engine issues, and you’ve got no chance. Either replace the ignition with a rebuilt unit, or with an aftermarket set, or adapt something from a much later model. You can do as many compression tests as you wish, but if you monitor for the presence of a spark every time you kick the bike, the true problem will become obvious. Still, it’s entertaining to watch you fumble around.
probably because he didn't want to spend money on parts, and bought the cheapest battery ever. , this is a common coil problem as they work intermittently
Okay Joe, I’m going to chime in as well….. I’m a 63 year old gal and been following you a long while, I’ve enjoyed watching you along the way- I grew up in my dads engine shop- saying that because Dad always said, The engine needs “spark” “air” and “fuel” to run.
You realized this bike had very weak spark! BAM!!! Your answer- wondering why you didn’t work on that before doing everything else that had nothing to do with spark?
At any rate- love what you do, love seeing these bikes come back alive.
Keep doing what you love but don’t over think 😊
I don't think I've shouted at a screen so much! You diagnosed a weak spark. Fuel was getting through because the plug was wet, also indicating a no-spark problem. So you then checked for wiring faults. Then you wanted to check the alternator/ignitor. Then you adjusted the timing, and it was downhill from there! You completely forgot about the weak spark and checked valve gaps, compression, valve lifters, carburetion, jet sizes, float hight... non of which would solve a weak spark which you had already discovered. Weak spark could be a failing coil.
I'm only at 35min mark, so hopefully you'll find it. Enjoying your work. 👍
I messaged him after the first video. I had all the information he needed as i have and have had many of these bikes and i also know exactly where if he needed parts he could get them. He replied and never returned to the message. Well. Here he is. Just fixing the starter would have taken him 45 minutes. He is a good mechanic but he should stick to easy Japanese bikes. These bikes are for men.
Also this bike is a 4000 usd bike any day if the week.
I couldn't say it any better. exacty what i thought. you knew the problem in the beginning.
Yes, I was saying to myself, "Come on, Joe, weak spark even in free air". It may be a no-spark under compression, even though that is eased with the lifters. I can't fault his dedication though, but he needed to stop completely and think. I would suggest he comes back to this one after a good while having some nice successes.
I was also screaming at the video about the weeks spark/no spark. This is the first video I have watched of him that he was off his game.
Fix the electric starter will speed diagnoses up and replace the rectifier and solder those wires, remove any twist connectors in the system.
Brush your teeth in a up and down movement, 4 times per brush length...
Tie your shoelaces with the right loop over the left loop,
Microwave your steak for maximum time efficiency
Exactly what i would do.
Get rid of the whole bike you mean. Lol.
100% weak spark. Get rid of those HOUSEHOLD wire nuts, solder those joints, check your COIL ground, double check OHM on the stator and STOP MESSING AROUND!! You KNOW what it is Joe!! That thing should be THROWING blue flames!! SPARK SPARK SPARK!!!
Agree. I also suspect a weak ground issue. Check engine case to battery for resistance. Household wire nuts on any machine must go, as well.
@@rayeaker1207 I am suspecting the same, grounding issue...
You can hate the HOUSEHOLD wire nuts all you want, but that’s obviously not the problem. If you’re entering it into a show then yes, get rid of them.
I used to ride old huskys and the best way I found to start left hand kick high compression bikes was to stand on a block and to bring bike to top of the stroke then kick hard I felt horrible watching you kick that old bike ....I am 50 and I love watching you repair old bikes have A great day from eatonville wa
I owned one of these, the stator is the problem, you have to get it rewired & it will start no problem.
They will be running one minute, you will turn it off and they will not start again. The stator has packed it in.
Late model ones has Japanese electrics which improved them greatly.
I used to have a spare stator sitting on the shelf ready to go.
Hope this helps.
The first thing I would do is get rid of those wire nuts and solder the connections.
How would that have helped it start?
It wouldn’t have a thing to do with it only if water gets in there over time will it be a concern.
@@Carboneye7 It's just the way I troubleshoot an intermittent. Before you start tracking down a ghost problem, fix any problem that you CAN see. Wire nuts are not made for motor vehicle connections. Like you say they may come in contact with moisture unlike when they are used in an inside setting.
@@oldguysoldbikes That's actually a very good call. My 2 Stroke KX wouldn't start after a very light ride one day. Never heard, felt or saw anything. My gut told me it was a weird, non-serious issue. Other people were going to extremes. Turned out to be an intermittent short in the wiring.
Had I listened to other people, I would have been practically tearing the bike down. In the end, it was a minute of soldering. I spent more time waiting for the soldering iron to heat up than I did actually working on it.
Shoddy connectors can definitely cause intermittent issues like that. @@Carboneye7
@@HexBMX the best tactialca is to work from simplest and quickest things on the list of potential problems.
That SEM ignition has always been a problem, Husqvarna used them and husaberg is just a Husqvarna after the engineers started their own company. Ditch the stock ignition for aftermarket and the bike will run like new. That's actually a great bike once the ignition is replaced. Common issues on all Husqvarna and Husabergs of those years. SEM ignition sucks, sometimes works, most time doesn't
Had a similar problem with a Husky. Coil ground! Looked good but after a good wire brushing on the frame and coil it would fire up first kick every time.
Completely agree! My buddy's XC had this same impossible to start issue, was a looked-good-but-was-bad ground connection. Re-do ALL the grounds as @coaterdave says, and you'll likely fix this. Also get rid of those wire nuts, they don't belong in a DC system nor on a vehicle. Never give up, never surrender!
Solder wire connections, check electrical continuity, stator, spark plug wire & coil.
You said it at least a dozen times "weak spark". When you have to turn out the lights to see a spark on the plug it's not good. You have compression and fuel so the only thing left is spark. I'm sure you'll figure it out but source a starter motor or the only thing you'll be riding is a wheelchair.
Your dumb summary (you have compression and fuel so the only thing left is spark) ignores many many aspects that make an engine run. Such as the right amount of fuel, camshaft timing, ignition timing for example. The fuel air spark story is way over simplified.
35:08 now your chasing your own tail by going back to fuel. The new plug is soaked in fuel. You don’t have a fuel issue. It’s coming down to that faint spark.
This is by far my favourite
channel. Good job for persisting Joe!
No doubt. But some of these comments are Fn brutal. I dig this guys content and over all vibe.
A few things to look at for weak spark, Check all your grounds, battery to frame,frame to engine, the coil and regulator /rectifier, maybe been mounted back over painted or rusted frame, kill switch wire maybe grounding out somewhere, bad coil lead to plug, plug cap cracked. pick up coil in stator not seated correctly.bad cable connectors, bad wires from the stator to connector, they sometimes disintegrate with heat and age, test your coil. good luck
SEM ignitions were a failure point and you cannot buy replacements.I have a 87 Husqvarna 510. Same issue. Very weak spark if any. Replaced with Vape ignition and now I have a very strong spark and the bike starts 2nd to 3rd kick. Left kickers are no joke!!! But when you can get a thumper to run. Lots of power...
We need to get some replacement kit and put sem in the bin.
2001 does not have SEM ignition. 1999 was last year Husaberg used them. Raced these for years. No issues ever with starting. First Ktm 520's used the exact same top end. He has no idea how to use the built in compression release. He will break the kick start gear if he keeps kicking against full compression. Used properly l could start mine with either foot. The bike works fine his issues likely stem from poor maintenance and a lack of understanding of the machine. Two failures in the time l raced these from 1996 to 2005. One was the previously mentioned SEM ignition on a 1999. Updated to the 2000 ignition and never had another issue. Second one was due to a case that got damaged in a cross country race and ran low on oil. Playing with timing without having the specs is foolish.
@@othgmark1 Yes its SEM it shows in the video its stamped SEM, i hade a Husaberg 550 2002 it hade sem. Ibelive they changed the ignition when they change to Kehin carb
With the engine being out of a different motorcycle who knows what he has.
@@othgmark1 I had a 2003 model which is pretty much exactly this bike and that definitely had the SEM ignition system on it as I had it blow out on me and had to source a replacement. 2004+ models switched to Kokusan.
The motor is a 470 which is the high performance moto version with 13 to 1 compression and will start better with race gas. The 400 and 501 were the Enduro motors. The starter is weak and battery small for the engine. I would replace the battery with a bigger CCA one and use the decompression lever to get it spinning easier with the starter. The FCR carb makes it start and run better.
I even saw a post about up sizing the main battery. And another about wiring a 2nd starter battery in series to 24v the starter Idk if it was a random post or not.
You can see where the previous owner was chasing his tail working on the spark problem, try removing the stator and insulating the wires that are up against the housing that have no insulation, or get a new stator.
There is this stuff called liquid tape that is good for that.
I feel the same. The weak spark is a big clue.
New stater.
It sure seems to be “leaking” spark. Test the plug wire, at the boot. I do not know how to do it, but I think when you measure the voltage coming through to the top of the spark plug, you will find that too much of the spark is LEAKING off before it gets to the spark plug. And why you must kick it over SO FAST to get ENOUGH spark that it fires. Alberta Jim
Could try the plug wire , they can corrode internally... try cutting it back at the boot end or replace it with another. Ohm out the coil... they fail over time.
The SEM can act up for sure..Iridium plug, swap the carb for a FCR..put Motul 300v 15/60 in the motor and you have a bike that will blow your mind😎
This is a good example of a machine that can explain why many GenX dirt bike riders, myself included, stick with our 2 strokes. Starting some of the earlier "performance" oriented 4 strokes was a hassle on the best of days.
Some older KTM was left hand kick
@@dylisaI remember those kick till Mondays. puking trying to start mine for a hour deep in the woods. It was also electric start but I never kept a hot battery
It's also why we all have one huge leg and walk in circles.
Just like this one ?@@dylisa
@@dylisa KTM were more or less Husabergs at one time. KTM bought them, took the knowledge and stole their slogan "Ready to race" before ending production..
Flow of this one was confusing. No spark detected with plug out. Next steps was to check timing and compression? Wouldnt you want to get a spark first?
i have had a few husabergs and they are known for having stator problems change the stator an it will fire up :-)
That Husaberg is a relic of motorcycle history. 70 degree motor started the line of the best balanced bikes ever made for dirt.
Husabergs are great.
Yes I had one of the 70 degree bikes, was great! The engine was awesome.
I've still got a Husaberg FE390 70 degree motor...pulls you through stuff that other machines won't!
That weak inconsistent spark is probably the problem
😱
Dont give up! its clearly a spark issue, fix that electric start so itll be way easier on your leg, get rid of the wire nuts and fix the weak spark.
one thing to try is if it has a light switch, turn lights off. if it doesn't have a switch then un plug headlight and tail light as they try to turn on when you kick it. if you have them disabled that will be more energy going to ignition while kicking.
I never thought there could come a bike that you can't fix and / or give up on it. It's sad to watch when such a positive calm person like you loses the spirit to continue. Just go for a walk with Vinnie and continue with a new project. All the best
You generate more complete, educational content than any other channel out there! Appreciate your effort sir!
if you wanted to be educated on how to get a weak inconsistent spark bike to start, this would't be the one to watch.
@@keithwarrington2430I would say this is the best because he shows everything in dept. I'm an electrical engineer myself and I can tell exactly what the problem could be besides that I learned so much from this video
I agree with everyone. Its gotta be the stator. Have you pulled the flywheel to see if you spun the keyway? Another off the wall shot is the bike was rebuilt. Maybe the piston is backwards. Cut all the wires back, solder them together. Trim the plug boot for sure.
You need to invest in a rear wheel bike starter that spins the back wheel to start the engine.
As someone who has owned one of these beasts, there is a VERY specific sequence to follow to get it to cold-start off the kicker.
1. Make sure the carb is clean, and you have spark. The stronger the spark, the better. Fuel on, choke plunger out.
2. Pull in the decompression lever. Kick the bike through about 5-6 times. This primes the circuits in the carburetor.
3. Kick through until you feel the piston coming up on the compression stroke. Pull the decompression lever, kick thru until you _just_ feel the engine go through TDC.
4. THIS IS THE MOST IMPORTANT STEP. Roll the throttle open all the way, hold it there for about a second, then release it. This puts a shot of fuel into the intake from the accelerator pump.
5. Get braced, and kick the bike over with EVERYTHING you've got. Don't touch the throttle all while kicking.
If the bike doesn't fire, repeat steps 4 and 5. These bikes were pretty lean on the pilot jet, and the choke doesn't give it enough fuel to really fire over cold. So you're using the accelerator pump in the carb to shoot in some fuel.
This carb doesn’t have an accelerator pump. It’s blocked off on this carb.
@@johnirvine3346 if it's a stock Husaberg with the Keihin FCR carb, yes it has an accelerator pump. Not sure why they would block it off.
@@matmaessen3688 if you watch the video. It’s a Dellorto and the accelerator pump block off plate is visible.
My best guess is spark because I worked on a lt250r that would start randomly and then die. Spark was weak but there. I looked at the stator and the pickup coil was broken. A new stator and coil fixed it.
I used to have an old CZ motorcycle that was left hand kick that started very easily. Loved that bike. Back in early motocross days its was CZ Bultaco and early Suzuki
How about you put together a portable starter motor like they have in F1. Like a car starter with a fitting that will fit the shift gear/shaft. You could have a little stand too. Then you could have a 12 volt car battery, and hit a button and turn the engine over as much as you want.
For that, you'd need proper housing on every bike exposing the flywheel, which none of them have.
@StkyfngrsZmooth2 you'd just need to spin the rear wheel. They sell this type of starter.
Yes, I was thinking about an electric impact
It has electric start. Never tried it
Just roll start on a hill like the old flat track racers, they would strip any weight they could including kick starters or starter motors, and just roll start...
Get one of the 20$ china coil , cdi , 4 wires , mag style , or 12 volt ,you only need the trigger , if it dosent spark then , try to install some other trigger , weak spark get killed by compression . Kohler makes a spark checker that simulates what compression does ( jump a bigger gap), Great content ! Don't give up !
😂The ending, "if you can come start it you can have it".
Man that got me😄.
I could just picture a line of guys out the garage warming up there kicking leg with one moto X boot on😂.
If and WHEN someone shows up to try you gotta get it on video.
I have a feeling atleast a couple are going to hit you up.
It's like the knights lining up to pull the sword from the stone! 😄
Great video as always Joe, I am amazed by your persistence! I know all too well the feeling of wanting to throw a bike down a cliff! But you totally got this one, if you don't start it nobody can! You know much more than I do, but I'd just mention my feeling is that the weak spark issue you identified is the culprit. It is not uncommon for dying stators to spark outside of the cylinder but lose spark under compression. Your stator does not look very good, it seems to show signs of corrosion/humidity. Probably will start right up with a replacement stator. If that does not work, maybe check for the resistance of the electric cables: last winter I worked on a 1962 motobecane with weak spark not starting that two shops had not been able to fix, and found out it had a wire corroded internally (with no external signs of damage) making a very high resitance and eating the spark out...
This bike should of came with a complimentary tube of Bengay for your poor knee, I give you credit!
It did when new 😂
Without the Ben
I'd go with stator coil continuity and earth/resistance check first, if all is good go to the next electrical part in line like the ignition coil. As many say weak spark is the issue, not the timing.
Hope you will find the culprit of the no spark issue!🤞🏻
Bad spark, it'll never crank easily until you get solid blue fire.
Hear hear, all the rest is wasting time. Valve adjustment, carb even the timing wont ever effect the quality of the spark.
Kind of obvious that it is coil-related. Check the connections as they are sensitive to contaminations, then try a different coil (and cdi unit).
Definitely need to put on a new stator and/or cdi box. Your values were lower than they should've been. If it's only sparking when it spins over fast that is definitely a stator or cdi box issue. I've had this similar issue on a few bikes i've worked on and the fix was a new stator and/or cdi box. Love your videos btw! Don't give up!
You got it started earlier when you bump started, since then you have messed with the stator, maybe try rolling it back to where it was and see if it starts easily when you bump start it, if it does then try adjusting it the other way. I am sure it's very finicky with the stator alignment, and I would also question those cams a bit too.
I’m glad to see you’re human and not every bike is a home run. It makes me feel better when I give up on a project lol.
If your spark is weak, it will spark when you have the plug out, but the compression will blow the spark out, could be why you get it to run occasionally as it will go when it hits mix sweet spot. Go over the wiring properly get rid of all the bad connections and re-check your readings on the stator and coil. Electrical work isnt a dark art if it looks right it tends to work right if it looks shit it is shit.
agree. the word "good" on the stator makes me wonder just how good it is.....
Maybe the first clue was wire nuts on the bike.....
The marettes should be your first clue.
Change the stator and the cdi unit
Pushing a non-running dirtbike uphill is the motorcycling equivalent of the Walk of Shame
In sweden all change to iridium spark plugs. That made them easy to start.
Dont give up !!!! You recognised it has weak spark but failed to fully check the sytem.... go to coil... test coil....
Dont underestimate your ability...
I’m still watching this episode and I haven’t seen the conclusion yet. Usually you are very methodical in your process. This episode, however, you proved to yourself that you lost spark, then you chased timing, and valve adjustment and compression?? None of those will create or negate spark. I’m still waiting to see you check the kill switch and the spark plug lead.
Stator is goosed, very common on these.
Change the damn coil dude its broken down gives some spark but not enough. If you would ohm test your stator you would know immediately if the stator was bad. dont know why you did all that other stuff and waste time if you had weak spark to begin with
You are very Talented and very strong about getting the work done.
Here is what I know for sure, this is a good bike, that is hard to start, if you don’t know how to start it.
try to take inch off the sparkplugs caple . it likes to corrode over time. the sparkplug cover also sometimes like to corroe inside.
I had one of these new in 2004. It was 100% reliable and started immediatley on the button. Very light, fast and just floated over the roughest ground. In 2004 they were the ultimate dirt bike, but yours seems to have had 20 years of neglect, so perhaps unfair to call it The Worst Motorcycle Ever Made. The 650 version is a beast of thing! All the best Paul.
Just a thought, When you had it partially firing on every kick maybe go the other way with the timing as it clearly got worse altering it the right way ;)
Add a relay power mod and run power straight from the battery to the coils.
Check for a nest in the exhaust. Its been sitting for 9 years. Make sure the exhaust pipes are clear of debris.
I think your problem is weak spark. When you were kicking it over (unsuccessfully), the taillight came on. Somehow you need more juice to the plug. Also agree: solder the wires together and get rid of those twist connectors. Finally, avoid all four strokes that kick start on the left.
This bike give a pretty good work out just trying to start the thing. A dirt bike that is cardio and strength enhancing.
dont give up on that bike joe! you have come to far, i know you can fix it, you got this!
You're starting it cold, once it runs, it warms up to some degree, then dies and won't restart. Like others have stated, perhaps a bad stator, but what about those janky wire nut connections? Something heats up just enough to cause an open? I would touch every electrical connection. Remove, thoroughly clean, and reattach. Connectors, ground points, all ignition related connections, everything. Just because it 'looks perfect', doesn't mean it always is. Check all fuse connections, as well as switch contact points, cleaning, and dielectric grease, as needed.
Yes, and judging by the corrosion on the frame and head studs, the first place to 'start' (heh heh) is to sterilize and re-do EVERY GROUND. No exceptions! And then ditch the wire nuts, at least replace them with proper connectors. Win!
Noooooo. Don't give up! There are a bunch of how to videos online showing you the start procedure. Don't you have a spare motor? Grab the stator off that. Maybe try disconnecting all lights and electronics not part of the ignition circuit. The stator should have two separate windings (one for ignition and one for lights). Lights shouldn't run off the ignition circuit. Once it's flooded you have to wait it out. If it doesn't fire after a couple kicks try again later.
Check that woodruff key on the flywheel on magneto
Never miss leg day with a Husaberg.
Just buy a Horsepower Ignition System for it if they make them for this model. For about $250 you’ll have and brand new ignition system that works perfectly.
Back in the day, I had a 2000 FC501. It was really fast in a straight line and could do endless wheelies! Unfortunately, had the same problem with it not starting and found out that it was the stator. 6 months later and 2 more stator replacements AND multiple fork seals, I’d had enough and just traded it for a Honda CR250 and left the European bikes alone.
Welcome to my world. Once you think you've completed a job, POW needs a little more tinkering. You have the patience and knowledge, mostly the patience. Cute little battery
24:30 I actually never thought or heard of this obviously genius technique of diagnosing with pressured air inside the cylinder.
you have a weak stater so when you kick it faster it generate more energy some of them came with a battery, the battery helps increasing the voltage and you get more spark. Look at the brake light in the video. when you have a weak stater take the bulb out so that it does not steal power from the circuit. regardless of timing spark is spark weather out or not of specs. but you should put all marks to align so that you can get it running easier when you solve your stater issue. finally check for a good ground.
Go to his house and fix the bike, start it make a video and you own a new bike.
@@royhenson3379 i live in sunny south florida he is not just around the corner. just helpful hints. This guy is great and i have learned more about his video than anyone out there on you tube. but i did run into a similar issue with a bike i was restoring and was not able to find the stater anytime soon. But what i did in order to test the motor until i can get the stater was to find a spark plug with a lower resistor value so i can get more spark, you loose alot thru the plug wire as well. sometimes its a simple ground issue.
I say that you are right marioross3524 no back tail light.
4 Srokes suck!!! I've rebuilt my 2000 CR250 3 times since I bought it Brand new. J&N innovations Suspension the bike has literally never let me down I'm 57 and still race OTHG on the GFI / AMP circuit and refuse to buy a 4 stroke. Love your videos keep em comin.
The kickmaster strikes gold again.😂😂😂
The old bump start is the final signs of desperation!😂😂😂 spark is the problem no doubt!! Get back on it Joe!! Dammit!!
Moisture in the stator case is the biggest problem. Be sure to open it after rides to prevent rust on the stator assy
Happend to me, I became a after ride procedure to spray the stator down with some WD40. Also the kill-switch needed WD40 after washing that bike. Man was it a PITA..
The starter relay needs to be connected to the battery, it also feeds power to the ignition box. That's most likely why you're getting weak spark unless you kick it as fast as possible. Because it's having to charge the cap off of the kick instead of the battery feeding the ignition.
No way I would kick start that thing in the garage, if I could jump it off a car battery.
I have noticed he does tend to do a lot of unnecessary kicking on the bikes he works on. After a dozen kicks quit till you find an issue. Like every one is saying it’s not going to start with a weak spark!
*(Look up TCI VS CDI)*
Well... I know some Models of Bikes Don't like to Start with kick Start when battery is "Stone dead" TCI System.
As in Low to no Spark. And When Battery is Low They don't like to run right.
Replace battery and they are Good. or Check for spark again with the Jumpers on her.
You Charged the battery up a slight amount... So this is why it worked for a bit.
"TCI takes a good amount more power from the charging system to power the spark plug in order to provide a longer and more powerful spark"
I see you got a new Battery , i did not Watch the Full video.(Yet) i am sure you talked about this already.,
just watched the video in full , makes sense why it will fire a little , you are kicking and charging the battery until the TCI will "boot"
then it fires , the battery cannot hold a charge / will not charge. the TCI needs at least 8V in the battery to keep the bike running right.
always fun to change a battery when half the bike needs to come apart to swap it LOL!!!!
Without the battery inplace. you can also do damage to the TCI system. Very important to keep the battery charged and not try to start with it off.
just sent an email to you so you see this before some comes and spends 5min and gets the bike for free lol!
My thoughts exactly. Put that new battery in and test the spark, sometimes the old bikes need a charged battery to produce a solid spark. Once it is running for a little while, this will not be a problem, but cold starts might need that battery.
It is quite possible that the weak spark is caused by an ignition component on the way to complete failure. A manual showing the required range of ohm and voltage readings of the various components would have been a great help.
I can imagine the last words to riders from the pit crew before taking off.. "What ever you do, don't stall it!"
Many Bikes have inherent Problems, understand those Problems, you can find solutions.
As a matter of fact, a good master of his craft can make solutions! Good Luck!
Remove decompression mechanism on the cam. Get to tdc and kick slightly past tdc release kickstart and then give it a big kick.
It sends me nuts watching someone kick a big 4 stroke the same way they kick a 2 stroke.
I have a xr650r and if you don't kick it right it will punish you
Backfires😮 hurt eh!
@@kiwiingenuity1677 I had an 83 KTM 495 when I was 16. That thing would backfire during a kick and damn near shoot me over the bars. These puppies these days know nothing about compression. LOL
I had an old CR500 left side kick. It helped getting a stool to stand on, we stood on the seat of a picnic table seat. Seem to help
the only thing that could be bad is the stator i cant think of anything else .. man you went trought the whole bike 😅 i admire the patience you have to work on this if it was me i would drive this thing into a lake and never look back 😂😂😂
or mabe just check everything in a logical way till you get a good spark.
Joe solder them wires on that stator and get rid of those wire nuts for starters. Do a voltage check on that stator and a ohm check and make sure your in spec then check the voltage regulator...
i might be wrong, but how does "kicking harder" make stronger spark if there is battery connected. Generated electricity from rotor goes to battery and from battery to coil to plug to generate spark.
So my guess is something between battery and plug, maybe a ignition coil?
Exactly!!
Dont believe it has a workin battery
@@robertdelinsky7247 he legit bought new one, 1:49
@@rik0_ Yes but never installed the battery at end of video is the old junk 1 that was in it
@@robertdelinsky7247 yea well that might be the problem? by simple kicking it wont generate enough current for a strong spark...
This reminded me a little of that Kids In The Hall episode where the car won't start. So they wash the windshield and spray paint it red to try to get it to start lol. Joe seems like a genius, far too sharp to not follow the spark. Hey, content creators have to create content.
Every time I watch one of your videos and my wife hears it in the background she says of watching the kicking king guy again. You must have a leg of steel.
Maybe get one of those spark testers where you can see the strength of the spark.
The husaberg is gonna be the new hovercraft out in the middle of the field marking it's territory
Had same issue , make sure you have the correct stator , my bike had the wrong stator fitted by the dealer
Tip, sit on bike backwards and kick it forward, thank you 🙏 😊
..your nuts will also say: "no thank you" in under 10 kicks...
2vintage i have owned 3 husaberg 2 of the same models as you`re 1 and they have all been a total pain in the butts to start even the 1 with a full rebuild,, all left hand kick start bikes are a pain,, but there is a kit you can get for $400 that turns them into electric starts and work great its what i did to all of mine and started fine after doing it..
Joe that Dooshburg doesn't even look good in the dark, don't give up! That spark looks really weak and intermittent that can't be right.
They are good looking machines Wym
@@broughton1835 Hah it was an satirical analogy, they are kind of cool. When it's running it will look great!
By the way, I really love your videos. I wasn’t being sarcastic. I admire your patience and method and I also respect that you published this video too. That’s cool to see. Because my threshold for frustration is so low I rely on folks like you. My son and I watch your videos a lot. 🤘
Let her go Joe,let her go.
Makes no sense if there's no spark. New ignition cables and coil at first, then stator/cdi.
Maybe aftermarket ignition stuff to get spark. Running Husas are real fun, don't let it down :)
OHM THE STATOR!!! YOU ALREADY SHOWED THAT YOU HAVE NO SPARK AND WEAK SPARK. DID YOU FORGET YOU BOUGHT A BATTERY???
I had one of these a long time ago, it taught me patience. I wouldn't trust any twists in the wires, can mess with the voltage/ohms. I would try to get rid of those wire nuts.
That moment when you say to yourself “why the hell did I buy this thing”. I’m sure we’ve all had at least one of those moments, in addition to “I never learn” when you do it again!
Joe, I commend you for being so persistent on this bike. I think most agree its some type of spark issue, but the problem is getting parts, if you do need a stator, coil, or rectifier. I think the "Joe Give Away If you can Start it" saves future knee surgery! Thanks for your great content.
Wire nuts on the harness? Who in the hell does that
🤣🤣🤣🤣🤣I had the exact same thought.
I guess you didn’t read my comment on your last Husaberg video. I spent a full year understanding the exact same issue you have here. The root cause is the marginal SEM ignition. Even when new they were troublesome. Add 20 years and undoubtedly a few minor engine issues, and you’ve got no chance. Either replace the ignition with a rebuilt unit, or with an aftermarket set, or adapt something from a much later model. You can do as many compression tests as you wish, but if you monitor for the presence of a spark every time you kick the bike, the true problem will become obvious. Still, it’s entertaining to watch you fumble around.
It won't start because it has a weak spark. It is so frustrating watching you find the problem and then ignore it.
probably because he didn't want to spend money on parts, and bought the cheapest battery ever. , this is a common coil problem as they work intermittently