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August 27th, 2015, 01:41 PM   #1
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I Ride: 2003 FE650E
2003 FE650 Electric starter and freewheel problems

Hey again guys!

I find myself in need of some advice from more experienced people here.

A while back I noticed that my electric starter would slip now and then. It would pull the engine over a few turns then spin freely until I let go of the button and tried again, or tapped it a few times. This got worse over a couple of days until it simply didn't do anything anymore except clicking the relay.

It still started fine on the kicker but when I stopped the engine I heard an electrical whirr. You know that second after combustion has stopped but the engine still turns over and stops, during that silent moment I could hear what sounded like the starter engine being dragged along by the engine.

So I pulled out the starter and it was worn out inside, the coal connectors were worn out and there was a mess of them inside the casing. Lucky for me it's an R6 starter a kind previous owner had installed so I could easily find a rebuild kit and got the starter running like a dream again.

But on to my problem, looking inside the engine it looks like the freewheel and the little cog between the freewheel and the electric starter, both have been spinning and scraping the case.

1 - Could this be because the starter motor didn't provide enough resistance being worn to hold it still, or do I have another problem with the freewheel?

Freewheel seems fine to me, I can rotate the small cog freely one way but not the other way.

2 - While I was in there I also notice two other odd things, the big nut on the crank was loose, I could spin it with one finger, can't be right?

3 - And the kick start shaft appears to be bent, can this be from silly people trying to kick a 650 without using decomp and literally bending the shaft?

4 - I noticed it's leaking oil here, new seal enough or do I have to replace the entire shaft?


Many thanks in advance!
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August 28th, 2015, 05:04 AM   #2
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you need a new/used kickstart shaft, don't mess with it. anything up to 2008 inc will fit.

you're right, the nut should n't be free. torque it to 89 pounds foot and use a bolt loctite of sorts.

use an O ring instead for the kickstart shaft to seal.

the free wheel and starter clutch spin so you need to fit an SRK - starter repair kit.

regards

Taffy
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September 1st, 2015, 02:30 AM   #3
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Thank you. Only thing I don't quite understand is how I would O-ring the shaft, once replaced, won't the ring just slip away if I simply replace the seal with an o-ring?
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