Any sprague gear slippage with 2003 and newer bikes?

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logjump

Joined
Jun 19, 2001
Messages
1,273
Location
Troutdale, Oregon USA 2005 FE550e
The weakest link on my 2002 501 e-start system is the sprague clutch (free wheel mechanism). You know, hit the e-start button if the motor isn't completly warmed up and hear the starter motor kick-out and spin freely without turning the bike motor over. I replaced the sprague clutch itself not long ago but it started slipping soon after.

I've noticed in the 06' parts catalog that the complete free-wheel mechanism was upgraded in 2003. I have not heard of the dreaded free-wheel spin on the 2003 and newer bikes so I'm wondering if any of you guys have had good luck with this upgrade. If so, I may be digging into my wallet soon!

It must be a good upgrade since some of you guys are cold-starting your 550's with the button!

I'm hoping all parts can be replaced with the clutch cover off, no splitting of cases.

800.40.020.000 free wheel gear 03
800.40.025.000 free wheel hub 03
800.40.026.000 free wheel 03

Thanks for your replies,
Log
 
I am very interested to know as well.

Double thanks for your reply, then.

Hey, Logjump, I did say thank you for the awesome bar risers, right?
 
My 04 slipped right out of the crate and still does cold unless you cheat it with the manual decompressor.
 
berger said:
My 04 slipped right out of the crate and still does cold unless you cheat it with the manual decompressor.
Click to expand...


Hmm, These are the comments I'm looking for. Thanks Berger.

Anybody else?
 
Well, I think that there is a displacement variable that needs to be factored in. Berger's is a 650. My 05 450 has never slipped. I haven't seen any complaints on the 550's either. I think the update may be more helpful as the displacement decreases.
 
Mine slip but it started to do that after I put the longer starter motor (same as on 550s and up). The original motor died on the trail.

I guess that with the new sprague and the 24v it would restart a lot more easily.
 
My 04 550 slips when cold unless I use the manual decomp. Its best to kick it though when cold, it usually fires on the 2nd kick.:)

Joe
 
Thanks for all the quick replies guys!

It looks as though it could be a waste of time and money to do an upgrade at this point. My bike has been firing flawlessly on the button when warm. I'll be happy with that and just keep tuning my cold kick-start drill. Maybe I'll start using my hand! :D

I was under the impression that all the new Bergs started cold on the button. Guess I was wrong.


Thanks,
Log
 
The free wheel mechanism (clutch) that was introduced mid 02 is built into the starter reduction gear set which was previously a solid machined gear assembly. Is recommended to fit this to earlier machines to prevent gear/sprague breakage if kick back occurs. As far as the Sprague assembly itself......the large outer gear/hub is the same 01-03, the sprague is the same 01-03, but the inner small gear/hub is different mid 02. Why....the gear teeth pitch was changed mid 02 on the counterbalancer, inner counter balancer drive shaft gear , outer balancer drive shaft gear, primary gear, and outer clutch basket gear. Mix 01 and 03 gears and is quite noisy. The noise usually happens when an 03 counter balancer is installed in an 01. Would have been nice if one could simply change the balancer drive shaft with it's machined on inner gear to an 03 assembly, but the 01 outer balancer shaft drive gear will not fit the 03 drive shaft. Install the outer 03 balancer drive shaft gear and you also need to change the primary gear. clutch basket, and inner starter sprague gear. Paranoid types will start thinking conspiracy theories at this point. (Actually they make a special double bearing balancer with the 01 gear pitch.) All this info is because if your 01 hasn't been updated, it can't be the freewheel mechanism that is slipping because you don't have one. Probably the sprague is slipping. They are quite delicate and small amounts of wear on the inner gears hub or the outer gears hub will make the sprague itself slip. Just remember the outer hub is the same 01-03 but the inner is different.
dan
 
that sir is in the doc!

remarkable, truly breathtaking and an honour, can i say, a REAL honour to have seen such a fine article! all your own work sir! marvellous! give yourself a pat on the back!

you have your place in history assured sir! it's called fettling.

i have 5 loaves over here BTW... :wink:

regards

Taffy
 
Gear Wheel Torque Limiter (aka Starter Clutch)
Part# 800.400.21100

Manufacture of this part was outsourced from KTM for a time. The supplier changed the torque/slip value without asking KTM. Some of these parts had a lower slip value resulting in the e-start slippage on some of the bikes.

Reportedly these bad gear wheel torque limiters only affected some 04 and 05 Husabergs. Replacement of this part is typically covered by a factory recall/warranty. Check in with your dealer.

I had this problem on my 05 FS650E. The Gear Wheel Torque Limiter replaced under warranty. Now the e-start works 100% of the time.
 
This recall should be checkable by VIN #, although this wouldn't apply to logjump. My 05 450 was not in the recall. BOSS checked mine for me.
I think Berger had his changed on his 650 with no improvement noted.
 
Had mine replaced under recall/warranty ('05 FE 550). Worked without slipping for two rides.

Oh well, I guess its a Husaberg thing 'cause its doing it again. Only when cold, but still a bit annoying especially when my KTM buddies stand around snickering while I repeatedly punch the start button hoping that it catches.
 
Now that it's been mentioned, I remember that mine had been done before I took delivery of the bike.
 
Great information guys. So the new (in 03) part numbers for the sprague/freewheel assembly are not an upgrade but just a change in gear pitch. That may explain the high whirring turbo-like sound I heard this summer coming from a certain 550. (Hello BrianSM). How easy can these parts (different gear pitch) be mistakenly mis-matched in a motor to an unsuspecting person? Kinda scarey! What were the engineers thinking?

On a side note, a bit of confusion can be had by the terminology of these parts. What Dan, dsducati calls a free wheel mechanism/clutch is referred to as the torque limiter gear by the book. What Dan and others, myself included, refer to as the sprague clutch is now refered to as the free wheel mechanism by the book.

I recently replaced my original torque limiter with one having a much greater break-away value so I have just assumed this is not slipping but the sprague clutch is. Not sure how one would know which is breaking away first and at this point, I'm not going to worry about it.

Log
 
Here you can see the result of the old solid starter gear.


Pic1

Pic 2


OLD VS NEW TYPE GEAR

Pic 3


This fault cost me allot of $$$, but what can you do
 
Hi Log,

My 04 550 when new would start on the button cold, but, as it broke in a bit it started Kicking out as you put it. Besides, most of the time I always start my bikes on the kicker when cold.

On my 01, the original sprague lasted up until the latest rebuild, approx 120 hrs, and I put a new one in after I had got it back b/c it wouldn't work at all anymore. Dan at Motoxotica figured it out over the phone that's what my problem was, and after installing it I haven't had any more problems with it spinning free when warm.

And after figuring out that the bushing was worn out on the communtator end of the electric starter motor, and having replaced that end of the starter motor the electric start system on my 01 works great.

Hope this helps,
 

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