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February 15th, 2011, 08:52 PM   #1
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From: New Zealand

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I Ride: 1999 Husaberg FE501E
Freewheel Clutch

Can anyone help with a 1999 FE501E to say which way the Freewheel Clutch Mechanism goes? Can it be put in wrong as I had a mate fix a broken Gearwheel on the Counter Balancer/Crankshaft the one that is held in with the small grubb screw. It has never started well since and now that someone else has it apart they question if the Freewheel Clutch is in correct.If any help is out there I can go riding again with confidence to use the electric start without it making a big noise at the end of the start cycle when the button is released. Cheers
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February 17th, 2011, 12:37 PM   #2
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I Ride: Husaberg FE501e 2003
Re: Freewheel Clutch

Originally Posted by prado10
Can anyone help with a 1999 FE501E to say which way the Freewheel Clutch Mechanism goes? Can it be put in wrong as I had a mate fix a broken Gearwheel on the Counter Balancer/Crankshaft the one that is held in with the small grubb screw. It has never started well since and now that someone else has it apart they question if the Freewheel Clutch is in correct.If any help is out there I can go riding again with confidence to use the electric start without it making a big noise at the end of the start cycle when the button is released. Cheers
just to be clear:
the clutch is the gear next to the starter motor

the freewheel is the gear over the clutch basket. it sits inside the sprague bearing. the sprague bearing CAN be put in the wrong way: there is a clip which must be visible on the outside like an internal clip yes? like the internal clip that holds a fork seal in?

a sprague gear will slip if you can spot tiny, tiny evidence of 'flat faces' on each sprague "roller". if those faces look 2mm wide then it is finished. the spring in the sprague bearing is weak from the factory and the starter clutch needs 're-packing' to keep it strong & tight at 25LB.

I hope this helps.

I hope you'll tell everyone here about your bike sometime.....

regards

Taffy
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February 18th, 2011, 08:01 PM   #3
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I Ride: 1999 Husaberg FE501E
Re: Freewheel Clutch

Thanks for the info.
My mechanic has found that the inner surfaces of the of the counter balancer gear and the intermediate gear are worn and require a new set (parts 27,28,29,30 page 44 of Parts Manual or Fig11 pg 45 of Workshop Manual). Over here they say those would cost $1500+ and they say the bike is only worth $2500.
Someone told me you can get the counter balance inner surface and that outer gear inner resurfaced but others say not worth it as won't last? Any help?
And then there is the Sprague (Freewheel clutch mechanism) not sure what they intend to do with that.
It's starting to look like taking all the starter gears out and making it kick start only which will be a drag.
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February 19th, 2011, 12:23 AM   #4
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I Ride: Husaberg FE501e 2003
Re: Freewheel Clutch

you sound like you're from the states. you've got engineers over there just like we do. get 'em resurfaced with new inner and outer rings, you can still pick up the sprague bearing but the spring is rubbish on the later bikes so i guess it wasn't a lot better then. if you're going to do it you need to upgrade your cam to the latest auto decomp so your starter doesn't fail under the pressure.

Orangeberg was offered all the stuff you want. get in touch with him. I've also got some stuff here if I look for it.

regards

Taffy
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