Go Back   Husaberg Forum > Mechanical and Technical > Mechanical

Mechanical Mechanical Forum - spinning bits and gyrating bobs

LinkBack Thread Tools Display Modes
August 27th, 2015, 02:41 PM   #1
Junior Member
Joined: Jun 2015
From: Norway

Posts: 16
Thanks: 0

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!
Attached Thumbnails
2003 FE650 Electric starter and freewheel problems-20150821_202040.jpg   2003 FE650 Electric starter and freewheel problems-20150821_202227.jpg   2003 FE650 Electric starter and freewheel problems-20150818_143214.jpg  
Bongo is offline  
August 28th, 2015, 06:04 AM   #2
Senior Member
Joined: Nov 2001
From: Ely, England

Posts: 15,464
Thanks: 408

I Ride: Husaberg FE501e 2003
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.


Taffy is offline  
September 1st, 2015, 03:30 AM   #3
Junior Member
Joined: Jun 2015
From: Norway

Posts: 16
Thanks: 0

I Ride: 2003 FE650E
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?
Bongo is offline  

  Husaberg Forum > Mechanical and Technical > Mechanical

2003, electric, fe650, freewheel, problems, starter

Search tags for this page
Click on a term to search for related topics.
Thread Tools
Display Modes

Similar Threads
Thread Thread Starter Forum Replies Last Post
electric start problems no more ljgiroux Electrical 10 April 12th, 2017 04:16 AM
2003 FE650 Electric Start Wire Guage? tdetlor Electrical 7 September 6th, 2014 07:33 PM
starter freewheel Taffy Mechanical 2 August 4th, 2008 02:09 AM
2003 FE400 problems problems problems.... Help! rmgcook Mechanical 4 June 15th, 2008 11:21 PM
Starter Problems on '05 FE650 rustie Husaberg 16 March 7th, 2005 01:17 PM

Facebook Twitter Google+ RSS Feed