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ratchett noise behind clutch cover

O

ozrider

Joined Jan 2007
152 Posts | 0+
Qld Aust
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
 
ozrider said:
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
Click to expand...

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
 
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
 
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
 
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
 
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..... ?
 
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
 
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
 
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.

regards

Taffy
 
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
 
While your there replace the bearings on the idler and starter sprague. Cheap insurance. Dont ask how I know :oops: But it can be REAL expensive if it breaks a long way out and you have to ride it in
 
boz! boz!!!!

oh no! it'll go straight to his head! he'll think he can fly now! :angel: :angel: :angel:

regards

Taffy
 
So, Just to update.
I give the dealer $1000 Au and he gives me a new clutch basket,starter freewheel assy, some bearings and gaskets which I have installed.Did 4 hrs riding on Sunday, noise is now gone, bike is the quietest it has been since I owned it and electric boot now works.
An inspection of the old parts and I find a damaged tooth on the basket (dont ask why I didnt see it first off) and it looks suspiciously like the imprint of a wayward needle roller!! You wouldnt believe the racket that one tooth was making :eek:
I have replaced all the needle bearings behind the clutch cover but....... :? now I dont know if I should look a bit further to see if I can find a faulty bearing or not as I didnt notice any needles missing from the ones I replaced.
 
Mick,

How many hours are on the bike?If its over 60 hours, I would check the cam follower bearings, especially the one on the Intake rocker arm,

These last about 60-70 hours and then start falling apart, shedding little bearing needles in the process.

That may be where the extra needle came from that got jammed in the clutch gear.

Regards,

Joe
 
Thanks Joe,
No idea of the hours, got it 2nd hand with no hour meter/previous history.
Will lift the top off and see what I can find.

Mick
 
Glad you got it running again! But I just wanted to know if it is only do your drains that spin backwards, or do you folks read backwards as well... :wink: :lol: :lol:
ozbasket.jpg
 
Hey Risky

Bcakwrads waht do yuo maen :? Bit of a reflection of myself.... a bit backward.
No Seriously, I am a bit hopeless with the camera (bit like my riding he he) Took about 5 trys to load it and that was the end result. I will work on it
 

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