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May 17th, 2007, 06:50 PM   #1
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From: Trois-Rivieres, Quebec, Canada

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E-Start problem Solved! Faulty Torque Limiter

Went to visit my closest dealer (Promotopieces, Mascouche, QC) today to check the primary gear nut and balancer nut and fix my starting problem.

When I met the owner of Promotopices last weekend and tried to start my 2004 650, he immediately suspected the torque limiter. When the motor was opened today, he checked the torque or the torque limiter and found that it was under the 10 Nm limit which immediately explains the slipping when I was trying to start my bike. Luckily, he had a replacement torque limiter which was installed. Result: perfect start without hesitation!!!

I had searched this site all over and red the owner's doc and never found anything about this torque limiter. Matter of fact, there is a technical bulletin that was sent to dealers in February 2005 that explained the problems and parts were covered under warranty. I uploaded the technical bulletin in my gallery. This is a very interesting document.

At the same time they Loctited the 2 nuts (primary gear and Balancer), and upgraded the water pump seal to 2007 part.

I had a big smile on my face when I left the shop! Hope this info will be put in the owner's docs so other people like me facing this problem will have use of their E-Start again.

Cheers, FRED.
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May 17th, 2007, 09:55 PM   #2
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Congratulations!

The dealer who I have meet last week told me the same.

I heard this also the first time.

Normally the freewheel clutch is the cause, but somtimes the torque limiter...
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May 18th, 2007, 06:35 AM   #3
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Actually, if I remember right, BOSS posted a thread flagging both issues (primary nut and weak torque limiter)quite some time ago! I guess it flew under the radar.
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