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January 22nd, 2008, 10:50 AM   #1
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removing e-starter

I finally got my jetting right on my 2004 450 and it starts every time wiyth 1 or 2 kicks, so I removed the battery and starter but I didn't remove the intermediate gearwheel and the freewheel from inside the clutch cover. I didnt think I'd need to, but now I have a problem although it might not be related.

I went for a 4 hour ride and when i got close to home it sometimes wouldn't change up from 3rd to 4th gear, or occasionally from 2nd to 3rd gear. Any ideas on this one?
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January 22nd, 2008, 11:57 AM   #2
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RE: removing e-starter

sounds like a worn gear selector drum? but it can't be!!

take the sidecover off and check what you did nd this time remove everything unnecassary. watch for needle rollers that may fall out although i've never heard of it happening.

the other thing to look for is the selector fork sticking and the star washer coming loose.

regards

Taffy
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January 22nd, 2008, 12:42 PM   #3
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RE: removing e-starter

Aren't there potential electrical issues running the bike without a battery?

Doesn't the charging system want/need a battery or suitable capacitor in the circuit to be happy?
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January 22nd, 2008, 07:01 PM   #4
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RE: removing e-starter

The FC had no e-start or battery. Plus, I've removed my e-start, battery and gears about 9 months ago with no issues at all. 2005 FE-550.
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January 22nd, 2008, 09:51 PM   #5
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RE: removing e-starter

well i was hoping no-one would say worn gear selector drum- thanks Taff

Celticdude, you're right the fc had no battery or e-start, but I put in the freewheel and gears, and starter during the last rebuild thinking I'd do the electrical stuff later. Once I got it starting easily with the kickstart I figured the extra weight of the e-start setup wasn't necessary
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January 22nd, 2008, 10:58 PM   #6
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RE: removing e-starter

yhing is with the gearbox, you have to throw money at renewing everything at once. i have done half at a time and it's not a good idea. the bits that are worn shag-out the good bits!

on mine it was worn dogs that wore out the selector drum IMHO because the gears were bouncing out and it was all whacking the corners off the drum.

regards

Taffy
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January 22nd, 2008, 11:01 PM   #7
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RE: removing e-starter

i have no lecy start.removed it and threw in a nice little ni-mh battery 12.v 4amp.....beautiful....no issues.as said loads of times before the ignition system is seperate from the lighting battery. good luck.if u need any pointers just ask
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January 29th, 2008, 11:50 AM   #8
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RE: removing e-starter

Got the side cover off today - no loose screws or bolts anywhere in the gearshift mechanism which i guess is good, but it doesn't tell me why the gears get stuck every now and then. Since I only have 4 or 5 hours on the engine since the rebuild I find it hard to accept its the shift drum because it looked ok at rebuild.

The selector fork spring looks ok and returns well when stretched by hand. The last 1 mm or so return of the selector fork is a little slow but i'm not sure how this can be fixed. Is it supposed to snap back real fast all the way to a stop?
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January 29th, 2008, 02:19 PM   #9
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RE: removing e-starter

it's your selector fork and all the info is in the doc somwhere like 'amber alert'?

regards

taffy
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January 31st, 2008, 07:00 AM   #10
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RE: removing e-starter

thanks a lot Taffy, removed selector fork, deburred it, removed starter freewheel and idler while I was in there, put her all back together and all is good! Went for a short but hard ride in the snow to test it and nearly froze to death but it feels good when your bikes running right, especially fixing a problem without splitting friggin' cases again!
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