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January 26th, 2009, 07:00 AM   #1
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free wheel gear? sprague?

I like many have a Berg that won't start on the electric button (Fe550e 2005).
It now has an R6 starter and bigger battery, valves and auto decomp checked and starts easily with the kickstart. (if it hasn't fallen off, though that's another story)

The starter motor seems to spin though and so I'm investigating the torque limiter and free wheel next. I have fallen into the trap of getting confused by the manual and the reference on the forum to sprague clutch's.
Is the sprague the free wheel gear and it's associated parts?

I have taken the RHS cases off and removed the Gear wheel torque limiter to test what torque it is releasing at. I have read the Doc's and am looking for around 15nm or I will try a shim in there to increase it.

The free wheel gear assembly is obviously harder to remove as it is behind the clutch and I don't want to remove it unless I have too. My immediate concern with this is the amount of play it has when the Gear wheel torque limiter has been removed. I can move it side to side by hand easily. should this part be more fixed or does it need to float free?

I hope someone understands what I mean by that or by chance has a bike apart at the moment and could check how much play they have.
Will ring Taffy soon to organise a shim and to discuss but advice and experience greatly recieved on this matter.
Kieran
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January 26th, 2009, 07:54 AM   #2
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RE: free wheel gear? sprague?

Just spoke to Taffy and things now much clearer, going to try a shim if I can get the thing apart. The amount of play is because the needle bearing is in the RHS engine cover so is held once reassembled. I wouldn't care so much if it had a kickstart on right hand side.
Owning a Husaberg is like a mechanics course, with this Forum as the classes and Taffy as the Proffesor
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January 26th, 2009, 08:07 AM   #3
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Re: free wheel gear? sprague?

Originally Posted by ManxBerg
I like many have a Berg that won't start on the electric button (Fe550e 2005).
It now has an R6 starter and bigger battery, valves and auto decomp checked and starts easily with the kickstart. (if it hasn't fallen off, though that's another story)

The starter motor seems to spin though and so I'm investigating the torque limiter and free wheel next. I have fallen into the trap of getting confused by the manual and the reference on the forum to sprague clutch's.
Is the sprague the free wheel gear and it's associated parts?

I have taken the RHS cases off and removed the Gear wheel torque limiter to test what torque it is releasing at. I have read the Doc's and am looking for around 15nm or I will try a shim in there to increase it.

The free wheel gear assembly is obviously harder to remove as it is behind the clutch and I don't want to remove it unless I have too. My immediate concern with this is the amount of play it has when the Gear wheel torque limiter has been removed. I can move it side to side by hand easily. should this part be more fixed or does it need to float free?

I hope someone understands what I mean by that or by chance has a bike apart at the moment and could check how much play they have.
Will ring Taffy soon to organise a shim and to discuss but advice and experience greatly recieved on this matter.
Kieran
Hi manx,

I had the same problem with mine 04 550 replaced the sprague clutch made no difference replaced the torque limiter, worked fine for a while then would only start when the engine was warm or hot, when cold the sprague clutch just slips.
So this weekend I had the job of replacing the water pump seal and fitted one of Orangebergs seal kits so while I was in there I removed all starter system, can't see the point of having a system that only works at 50%.
Must say the engine runs a lot quieter without the idler gear whizzing around, that gear must spin a some serious rpm.

If you are hearing a fairly loud squealing noise it will be the limiter if it's a whirring sound it will be the sprague.

Regards

Sparks.
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January 26th, 2009, 10:47 PM   #4
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RE: Re: free wheel gear? sprague?

You can do the old cut an inch of the sprague spring. It works a treat.
There's another thread on how to do it.
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January 27th, 2009, 05:38 AM   #5
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RE: Re: free wheel gear? sprague?

Clamped the torque limiter and it turned with less than 10NM so definately not as it should be.
I've since tried to get the nut off to put a shim on, but it's so shallow that i'm in danger of rounding it off and it won't budge.
Anyone done this mod and how did they do it?
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January 27th, 2009, 09:31 AM   #6
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Re: RE: Re: free wheel gear? sprague?

Originally Posted by ManxBerg
Clamped the torque limiter and it turned with less than 10NM so definately not as it should be.
I've since tried to get the nut off to put a shim on, but it's so shallow that i'm in danger of rounding it off and it won't budge.
Anyone done this mod and how did they do it?
Hi Manx,

I locked the smaller gear of the limiter in my lath chuck and didn't seem all that tight.
I would say you want to be looking around a 10 thou shim, don't over do it or you might end up loosing teeth off one or more of the gears.

Regards

Sparks.
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January 27th, 2009, 09:45 AM   #7
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RE: Re: RE: Re: free wheel gear? sprague?

Hi Sparks I've managed to get the smaller gear off the back but cannot get the pin out of the large gear (so that I only have it in 2 pieces instead of in 4 pieces). I've tried hitting it and pressing it and it is now in my oven. Without the pin section out obviously I cannot put the shim between it and the curved washer. Did yours come apart easily after you removed the smaller gear?
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January 27th, 2009, 10:00 AM   #8
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Re: RE: Re: RE: Re: free wheel gear? sprague?

Originally Posted by ManxBerg
Hi Sparks I've managed to get the smaller gear off the back but cannot get the pin out of the large gear (so that I only have it in 2 pieces instead of in 4 pieces). I've tried hitting it and pressing it and it is now in my oven. Without the pin section out obviously I cannot put the shim between it and the curved washer. Did yours come apart easily after you removed the smaller gear?
When I undid the nut the two halves just came apart, sounds as though you nut is stuck in the larger gear, but there is nothing to hold it in, strange.

Regards

Sparks.
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January 27th, 2009, 10:15 AM   #9
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RE: Re: RE: Re: RE: Re: free wheel gear? sprague?

Does anyone how much is a new one of these?
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January 27th, 2009, 10:23 AM   #10
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Re: RE: Re: RE: Re: free wheel gear? sprague?

Originally Posted by ManxBerg
Hi Sparks I've managed to get the smaller gear off the back but cannot get the pin out of the large gear (so that I only have it in 2 pieces instead of in 4 pieces). I've tried hitting it and pressing it and it is now in my oven. Without the pin section out obviously I cannot put the shim between it and the curved washer. Did yours come apart easily after you removed the smaller gear?
In the Owners Doc, under engine upgrades its a picture of the part splitted. If its help.

Regards
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