FE650 starter drive broke!

cowpoke · Nov 16, 2005

I got hold of a ' 04 FE650 e/6 this week and have a big problem. The starter countershaft gear w/ one-way sprag in it broke most of the teeth off on the clutch hub end (outside). I would think this is highly unusual but not a pretty picture. The case is slightly buggared behind the gear and the needle bearing is whiped out and the cover is slightly messed up. Any good source in US for parts on hand and ,more so, I need some parts pictures and mechanical picture of left case and innerds. Thanks fo any help to get me started.

dirtberger · Nov 16, 2005

Look on the dealer list or go the the Husabergstore.com

JoeUSA · Nov 16, 2005

Go to www.husaberg.se

Check on downloads, former files, and you will see in 3 languages, the Owners , Parts, and repair manuals you can download for free.

Look through them and come back with your questions.

Joe

sandskipper · Nov 17, 2005

cowpoke,

Are the gears that you are referring to shown in the parts diagram that you can download below? This is out of an '03 parts guide as I was unable to find one for the '04 in an english version but this should be about the same. Please give us some more info so that we may be of more help in diagnosing the problem. I also included the following link to a picture of my bike with the side cover removed. My bike is not e-start but may help as it shows some of the other gears.

Pic of side cover removed

Regards,

cowpoke · Nov 17, 2005

Thanks for the replies.
Sandskipper, the downloaded pic did give the correct gear # 12 "free wheel inner part" and #11 needle bearing. Thanks for your depth of help. I have "dial up" out here in the country and its a pain to download manuals,or parts cat. Where should I start to hunt these parts down since Colo. doesn't seem to have a dealer anywhere near Denver. Pardon me if I missed someone!!! Thanks again for quick responses.

sandskipper · Nov 17, 2005

cowpoke-

Being that my bike is a "kicker" only and not e-start I am little help on this. There are however many others here that would be considered knowledgable and dare I say "experts" on these leccey starters and their engagement systems. I am sure someone will come along shortly to lend some advise to you on this mishap. In the meantime can you tell us a little more about the damage to the case and the side cover? Did the damage occur from the "free wheel inner part" or does it look to be something that may have occurred at a earlier time? What do you mean by the case is slightly buggard; cracked, ground/chewed up, rubbing??? From the sounds of what i've herd so far I am beginning to think that the needle bearing was defective or just gave out prematurely and this is what caused your dilemma, but that does not explain the missing teeth on the free wheel gear. If you cannot post up some pics, please use your keyboard and paint us a picture with words so that we can be of better assistance to you... Hope these help.
In the meantime, Dan over at MotoXotica (california) is a good bet when it comes to finding parts. He has most stuff in stock and has great prices. Give him a call (717)446-4282 or visit their web site at: http://www.motoxotica.com/ you will be replacing at least two parts as we can tell so far so might as well get them on order now. Best of luck and give us some more info so better help can be had.

Regards,

cowpoke · Nov 18, 2005

Howdie, Sandskipper. Thanks for the interest. This is what I can see. Nothing could be done inside the clutch cover so when I pulled off the side cover the end of that "free wheel" shaft, that rides in the outer case needle bearing, was broken OFF!! The piece fell out of cover and when I wiggled the rest of the shaft it was real sloppy in the engine case so I proceeded to further disassemble. It was also quite noticable that 9 of the 13 teeth on that inner free wheel were broken off. That end of the assembly engages the "ring gear" on the clutch hub. The clutch hub looks fine though!?. So, as the broken shaft vibrated around because one end was not secure, the case took some abusive marring and the needles fell out of the bearing. The outer cover got some gouging around the needle cage but the bearing stayed intact. Then to add insult to injury, I messed up the case a little around the water port O-ring (we won't say much more about that tho). Anyway, I need the free wheel part, water pump impeller shaft seal and pin(impeller was hard to get off), cover gaskets and some good service pics. on that side to make sure of cam timing,etc.
Thanks a bunch. Don
P.S.--- I finally downloaded parts pics. Thanks.

JoeUSA · Nov 18, 2005

Next time you remove the water impeller warm it up a little with a heat gun first. Maybe a hair drier will even work.

Joe

cowpoke · Nov 20, 2005

Thanks Joe. The plastic impellers I work on(cars) are already broken in two, so I don't have to get them off. I didn't stop to THINK first. Thanks for all responces , looks Like I'm on may way with parts help from MotoXotica and hopefully he will be able to send some assembly pics/info. Or maybe I should buy a manual !?!? Thanks again. Don

schwim · Nov 20, 2005

Hi Don,

You can get the official parts and owner's manual as a download here on the husaberg.se site.

,
json

cowpoke · Nov 20, 2005

Thanks Schwim. I downloaded 04 manual from your lead. I missed that somewhere! It took a while to download but looks great and will definitely help. Much help from all & greatly appreciated. Dan from MotoXotica called back on Sun.!! to tell me he had all parts but one needle bearing. Thats incredible. Thanks to all. Great site. I might even keep this bike!!! Don

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