New Used 2012 Husky Te310 Can't Get Running

[brettob]

I picked up a pair of bikes from a lady cleaning out her garage. One of them looks like a beautiful 2012 TE310. When powering it on, it shows it only has 880 miles and 40 hours of use. Not sure if this is correct or not, but I would love to get this running.

Originally it had 4 problems:
1) No Kickstarter (anyone got one I can buy?)
2) The electric start only clicked
3) The engine appeared to be seized (wouldn't rotate with bump starting)
4) It had a JDTuner on it and the injector just squirted out continuous high volume of gas upon power up

With the engine not rotating, I was concerned with maybe a seized piston, crank, etc. So I tore the engine out of the bike as started to tear it down. Inside, it looks brand new! Head and bearing surfaces look perfect, piston and crank not seized, but when I removed the starter, I heard a binding pop. Looks like the seizing was due to the starter and the ring gear. I have removed them and plan to convert this bike to a kick start model only.

Now on to the not running condition. Of course I have removed the JDTuner as it appears to be defective.

I am bump starting it via push bump starting or pulling it behind a vehicle. It now will sometimes start and will run some at low idle, but dies / seriously stumbles and dies when trying to accelerate.

Here is what I have confirmed OK:
1) Flywheel key not sheared and it fires near Top Dead Center
2) Super strong spark (nice and blue with about 25,000 volts according to my gap tester)
3) Fuel Pump runs upon key on and also during engine turning over
4) Cleaned the injector and used a tester to validate it can consistently provide fuel with a decent spray pattern (injector is the standard yellow 4 port type)
5) Camshaft gear timing is correct and verified by Top Dead Center spark and also alignment marks on case and gears (Validated via timing light)
6) No error messages on display

Here is what I have found that has been done to the bike:
1) O2 sensor removed
2) FMF Factory 4.1 exhaust
3) Power up screen shows a E41E 2099 message (which is maybe the ECM level or something?)
4) In the upper right corner of the display, it shows "Race Mode" (and the button to change the ecm running conditions does nothing that I can tell)

I am really scratching my head as to why it is not running correctly (barely can keep it going)

Because it is fuel injected with an ECU mapping, I have no idea as to if the program in it is really good for the bike set up. See attached files for what I am guessing as to the type of program is currently on the bike.

I also learned about iBeat and cables from gracious members of this group. I have iBeat up and running and the bike has no errors and the sensors seem to be operating similar to what I would expect.

To make any engine run, you need fuel, spark at the right moment, and compression. I am sure the spark is strong and working at the right time. I have not yet check compression as i have no starter or kick starter. So I think I have a fuel problem.

I have taken off the throttle body and removed the spark plug so I can spin the rear wheel in 6th gear to turn over the engine. I see a fine mist from the injector upon turning over the engine and I always hear the pump running upon rotation. But when I bump start it behind another vehicle, I am guessing it is starving for fuel when cracking open the throttle.

But since the injector tested fine on the offline tool, it almost seems like the ECU is not properly giving the right command for fuel levels???

I wish I had access to another te310 to where I could maybe swap my ECU into someone else's bike to see if it works properly, or maybe borrow someone elses ECU to test and see if my bike works. ANY ONE OUT THERE WILLING TO TEST OR BORROW AN ECU?

ANYONE HAVE ANY IDEAS ON WHAT I SHOULD TRY OR CONFIRM NEXT?

ANYONE HAVE A SOURCE FOR A KICK STARTER OR BE WILLING TO SELL ME ONE?

DOES MY POWER UP SCREEN OF E41E 2099 and the iBeat screen ECU version #E10RA04 mean that I have some special ecu upgrade that needs something like the JDTuner to work properly???

Thanks so much for any thoughts, suggestions, or direction

Brett

 

[pvduke]

starting system: obsolete. go used on fleabay etc.
check compression. might have been hydrolocked (you said it was seized AND dumping fuel). if comp is low, check deck height and valves for seating/bent stuff.
check valve lash and cam timing.
call JD for ? on that ECU. shop for known good used controllers etc. going back to stock if you can THEN going forward is always the best option.
stop towing it to start it as it might be flooding or yer gona bend something...like a rod or....

 

[brettob]

starting system: obsolete. go used on fleabay etc.
check compression. might have been hydrolocked (you said it was seized AND dumping fuel). if comp is low, check deck height and valves for seating/bent stuff.
check valve lash and cam timing.
call JD for ? on that ECU. shop for known good used controllers etc. going back to stock if you can THEN going forward is always the best option.
stop towing it to start it as it might be flooding or yer gona bend something...like a rod or....

Great thinking and response. Much appreciated. I checked compression tonight and got 90 psi (of course this is with the automatic compression relief working, so I am not sure what this number should be... Does anyone know the compression we should get on a 2012 Husky TE310?

Valve lash looks good and I am sure the cam timing is correct as I did it per the manual and also used a timing light to verify the holes and cam cap cut lines match up at TDC.

I guess I was not clear enough on the seizing. When disassembling it, everything was completely free except when removing the starter. This is when I got a binding pop and everything turned perfectly. As for when the gas was entering the bike, I disassembled the engine prior to trying to use and force to rotate the engine. Inside, no hydrolocking, as all the gas made it down to the crankcase to mix with the oil. Of course all of this is changed to a new filter and oil.

Tonight tore into the JDJetting box as I never got any response back from the company on my questions. Thought I might learn something. Found out who ever put this system on the bike used a red colored battery connector, but the circuitry of the JDJetting module is requiring this to be a ground. When we put the battery in the bike, we connected red battery leads to the positive connecter and this must have made the JDJetting board go crazy and directly open the injector. I have not tried running the bike with this module as I will be asking the company if there is permanent damage to the module if the ground wire is connected to the positive lead. Once I know if the module is fried or not, if it is good, I may put it back in at some point to see if it does anything.

Because it is so late to try starting this in the subdivision, I now have the spark plug removed, and am spinning the tire in 6th gear to make the engine spin. Under my hand spinning, I see a mist coming out of the injector. Wish I could spin the rear wheel fast enough to see if the volume of fuel increases with higher RPM's. iBeat shows when I spin it by hand to be having an injector pulse width of about 4000 ms when I am spinning it at about 100 rpm or so

Will try more in the morning when I get some sleep.

 

[brettob]

A kickstarter lever would sure help. From what I see online, it appears the 2010 -2012 TE250, TE310 and the TC250 used the same part. Originally a 8000A7092 which then was replaced by a 8000h2252. Anyone out there have one for sale? Or does anyone know of an aftermarket one that would work on these bikes?

 

[pvduke]

comp: 90 @ slow crank with decomp engaged is just barely enough to light it. it should be enough to get a fluff or fart out of it. once it lights the decomp disengages. i dont know how to disengage the decomp for a static comp psi test. anyone?

mechanical timing: if it's all good, your good.

true spark timing: verify that. if to spec, i suspect yer box is toast. ive never seen one work after improper install, esp when Red n Blk are crossed. replace it with known good OE or something. you have comp, fuel, but what about spark timing?

used parts: again- e-bay is yer best bet...maybe over-seas used parts hoarders can help. sometimes you just have to make alot of calls and pony up and toss the stuff that don't work in the spares box.

 

[brettob]

HooRay!!! Got the bike running a while ago and thought I should update the thread with what I have found.

#! issue is although I was getting great fuel flow into the injector, the pressures were lower than the injector could handle (25-30psi) and the system is looking more for around 45-50 I think. REFLECTION LESSON - ALWAYS MEASURE THE PRESSURE AND FLOW on a fuel injected bike! Tore the tank apart and ran the fuel pump outside of the tank and the filter had a super small pin hole leak in it. It could squirt fuel about 6 feet. Changed the filter and now it is golden.

#2 Sent the JDJetting 6X tuner off to the manufacturer for testing and they found it was fried and didn't adjust anything. So I purchased a replacement one.

#3 With the kickstarter missing and the starter removed, it is a real pain to bump start it for an old man. Tried a used Ebay one for the bike and also a Moose Racing one they thought would work and each had a diameter that was bigger than my actual splined shaft. Will post a new thread on this issue.

 

[pvduke]

nice...told ya the box was poofed, the magic blue smoke escaped!

good on ya....