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January 20th, 2007, 08:56 PM   #1
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ratchett noise behind clutch cover

Hi all,
My fe 501 has suddenly developed a rather loud ratchetting noise from behind the clutch cover. All was good, out riding and having a ball. Stalled the bike and upon restart (kick) the noise was there.I have removed the clutch cover everything looks good re fit cover noise still there. Remove cover again, remove kick start gear and e/start gears, re fit cover and roll start. Noise is gone. I was thinkin it was the kick start paul not retracting far enough, but a long hard look in this area and I see nothing and operating the kickstart with the gear removed, the paul seems to be retracting as required.Any ideas because I am sick of removing and refitting the cover with no result...... basically sulking now. Think I might get rid of her and upgrade to a newer girl maybe fe 550.

Mick
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January 21st, 2007, 09:26 AM   #2
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Re: ratchett noise behind clutch cover

Originally Posted by ozrider
Hi all,
My fe 501 has suddenly developed a rather loud ratchetting noise from behind the clutch cover. All was good, out riding and having a ball. Stalled the bike and upon restart (kick) the noise was there.I have removed the clutch cover everything looks good re fit cover noise still there. Remove cover again, remove kick start gear and e/start gears, re fit cover and roll start. Noise is gone. I was thinkin it was the kick start paul not retracting far enough, but a long hard look in this area and I see nothing and operating the kickstart with the gear removed, the paul seems to be retracting as required.Any ideas because I am sick of removing and refitting the cover with no result...... basically sulking now. Think I might get rid of her and upgrade to a newer girl maybe fe 550.

Mick
Hi OZRIDER,
"I was thinkin it was the kick start paul not retracting"
Based on your description you are likely in the right area.

I would insure complete proper assembly, start the engine, note noise in question and then engage the kickstart. If the noise remains the same you have at the very least isolated your problem.

Hope this helps.

Dale
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January 21st, 2007, 11:05 AM   #3
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Thanks Dale,
Now that you mention it I am pretty sure the noise is the same when I move the kick start..... I might remove the paul and give it another try. I really cant see what might have changed for this to start happening. I have noticed the paul does not retract all the way back though, it sits about .75mm from the fully retracted position.
I will report back.

Mick
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January 21st, 2007, 02:07 PM   #4
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there is the chance that the paul has fallen off the crescent. it is just about possible for the boss to be squeezed on all wrong.

regards

Taffy
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January 21st, 2007, 02:33 PM   #5
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Hi Taffy,
when I remove the kick start gear to expose the ratchett/pawl assy everything is in place. The only thing I can see is that the pawl is not quite fully retracted - about .5 - .75 mm off.When I actuate the kick start with the gear removed, the pawl seems to operate correctly, follows the half moon plate around and opens out to the engage position as it leaves the plate. The plate looks good with no damage or wear. I can spin the kick start gear by hand and can hear the pawl clicking on the inside of the gear, but the shaft is not supported on the outer bearing as the clutch cover is off. I can also stop the clicking noise by moving the outer end of the shaft slightly toward 4 oclock position.

Mick
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January 21st, 2007, 11:15 PM   #6
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So I put it back together minus the pawl and spring, noise is still there.....??? Pull apart again and reassemble minus pawl, spring and kickstart gear, noise is still there....#*%???. Pull apart again refit pawl,spring and kickstart gear, reassemble minus e/start clutch assy and idler gear, noise is gone. I am at a loss, Iam now thinkin there is something wrong with the e/start drive /clutch but I dont see anything out of the ordinary, anyone got any ideas as to what to do next. Should I just replace the e/start clutch assy (only works when it feels like it any way) and see what happens or..... ?
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January 22nd, 2007, 01:09 PM   #7
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not sure if you have read the owners doc but there is an article on the different starter spragues that were changed guess when!

go check the doc and the attached hyperlink to thread with the answers. pretty sure that this is it mate!

regards

Taffy
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January 22nd, 2007, 10:05 PM   #8
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I hear what you are saying Taffy and I am a bit confused, I have read the Doc on this issue so I can see where the problems can start. If I assume there may have been a inncorrect gear/s installed, I would have thought the noise would have been there all along not just developed suddenly after I restarted. I f there has been inncorrect gear/s installed, which ones would they be, do you think it may just be the inner gear and what do I look for to determine the problem gear/s? I am unable to find any part #s on the gears.

Mick
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January 23rd, 2007, 01:40 AM   #9
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i see, well the ratchet is the only thing i guess that can afford to make that noise without getting broken. so anything else has got me flumoxed.

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Taffy
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January 23rd, 2007, 02:07 AM   #10
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Well, I guess when all else fails just throw money at it.
I cant see anything but maybe there is some gear damage that I am overlooking on the inner freewheel gear or the clutch basket ring gear
The starter freewheel mechanism has been operating poorly since I have had the bike and given that the noise is gone when this assy is removed I will order and install a new one and see what happens. The only other part that is moving and in contact with the free wheel assy is the ring gear on the clutch basket.......maybe I replace the basket as well.I will let you know what happens after that . I am clutching at straws now but what else ? thanks again for your input.

Mick
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