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June 3rd, 2004, 12:28 PM   #1
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Whining noise

Since replacing the centre of the starter sprag after some teeth broke off, there has been a loud whine from the clutch side of the bike. I've had the clutch cover off a few time but cant see anything wrong. Has anybody has anything like this before or any ideas, got it in bits just now and I'm gonna replace the bearings for the starter sprag just in case, but they look OK. This is driving me nuts

Any help appreciated
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June 13th, 2004, 10:28 AM   #2
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OK, no one has had any strange noises from a berg engine well how about a bit advice on stripping it. I have it all torn down to the motor to little bits and found the balance drive shaft bearings had it. Having decided to replace all the bearings as ther was quite a lot of debris inside, my trouble now is can't get the counter balance of, and it isn't shown in the workshop manual. Checked the parts manual and it shows a circlip between the two bearings but I think this just seperates the two bearings. Does the counter balance just pull of
Come on guys give a newbie a break (and some advice) please
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June 13th, 2004, 11:15 AM   #3
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Hi Yoshie,
The balance assembly is a slip fit onto the crankshaft. Using suitable means (ie puller or you may use to small pry bars to wedge the balance unit free) pull the balance unit straight off the crankshaft axle.

Hope this helps.
Best Regards,
Dale
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June 13th, 2004, 01:20 PM   #4
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There is a guy in Phoenix here that is having the same whine noise from the clutch cover area after he replaced his starter gear. He is at a loss as well. He has had the clutch cover off a few times and can not locate the origin of the noise. You are not alone.
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June 14th, 2004, 01:26 PM   #5
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Cheers guy's got the counter balance weights off OK and have ordered all the parts to rebuild, will post the out come of the rebuild hopefully the dam whine will be gone.

Yosh
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June 14th, 2004, 04:08 PM   #6
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Hey Yoshie -

I ran into this same problem when gluing my 2002 back together. There is an early and a late release sprag gear and the two do not interchange. The difference is not noticeable to the eye but will result in the whining you described. Triple check to make sure you have the correct part for your bike. If you installed a late (2003 or newer) clutch assembly, you will need the matching sprag.


~ Ken
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June 20th, 2004, 07:36 AM   #7
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I think you've nailled it , just checked the free wheel inner and its for the 01 model, it's got part no HB 250 248 stamped on it. My bikes a 03 model it should be a 250 273. Possibly stripped my engine for nothing, bugger, still replaced the timing chain and bearings and the balance drive shaft bearing was a bit rough.
Will be onto my supplier first thing tomorrow morning and will have a word about his parts supply

Thanks again PowerCell
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June 24th, 2004, 10:53 PM   #8
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I have just put together a 2001 fe501 and used a new inner for the sprag part #250-273 I believe and 2001 should be 250-248. I also had a hellatious racket coming from the clutch side. I was sure I left all my wrenches inside it was so loud. I removed the sprag and the noise is gone. I will ride without the e start this weekend and try to sort it out next week. Funny thing I liked the new sprag inner- it didn't freewheel when cold and started the bike cold right off. I sure love this thing when it goes and the first 10000 miles were great but it is getting to be a pain in the ass. Time for a new one me thinks.
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June 24th, 2004, 11:28 PM   #9
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Bob, same problem as me, except the other way round, 2001 parts fitted in a 2003 bike. Hey, perhaps we sould swap freewheel hubs or keep the hubs and swap bikes

My dealer is now sending me a '04 freewheel inner, hope its OK I would rather have a '03 (250-273) one.

Does anyone know what the difference is with the inner, is it the pitch of the teeth, it's not much, I can't see any difference.

Hope you get it sorted out, it's not the bike fault that dealers sent us the wrong parts
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May 2nd, 2011, 05:56 AM   #10
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Re: Whining noise

I'm dredging up this old post from long long ago to add my experience.

I have a 2002 550, my sprague was worn so I read the doc (over and over). In the section titled "Amber alert", it advises about the changes in sprague gear designs that cause the infamous whining noise if you don't match the correct parts. The doc states that you have to match all the sprague parts "as a set", so I ordered all the later model parts for >2004 (inner, outer, and the sprague itself)... I did this thinking I would just replace everything and do it as a set to avoid the whining problem. Well, the damn thing sounded like a jet engine and the inner gear broke three teeth off after about 5 hours of use.

So... the doc is a bit misleading in my opinion. What seems to be important here is that the pitch of the teeth on the clutch basket, the inner sprague gear, the crank and the counterbalancer must all be compatible with respect to the pitch of the teeth, otherwise it will whine loudly and potentially break things as happened in my case.

So, I'm a bit unsure now if I can still use my new sprague setup, but simply install an older style inner gear. I would think that the only thing that matters is the dimension of the "drum" that the sprague gear grabs on the inside... the older part would have the correct gear pitch to prevent whining.

Anybody know if the older inner gear will work with the other >2004 sprague parts? I haven't pulled mine out yet to measure.

It did e-start cold/hot, no matter what conditions (for the 5 hours before it broke).

Thanks!
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