broke new sprague gear

DuaneB · Apr 30, 2011

My 2002 550 sprague was slipping so I replaced the entire assembly (inner hub, outer hub and the sprague).. but I originally thought I could use the newer parts from a 2004. This worked, but the bike had the infamous high pitched whine (I was gonna get some Pratt & Whitney decals for it)... although the starter worked perfect, I stalled the bike today in a mud hole and it snapped three teeth off the sprague gear that engages the outer clutch basket.

Some guys have reported running mis-matched gears for a long time with no problems, but for me it only lasted about 5-6 hours. No harm done, I didn't run the engine afterwards and the three teeth have been recovered... I was a bit lucky on this one.

ElSnorro · May 2, 2011

I have the high-pitch noise also, 2004+ (pin style) clutch basket and 02< gears on de CB-drive and crankshaft. (no electric start)

Although it works perfectly for about 20 hours now, i am searching for a newer set of gears to get rid of the noise.

popup · May 2, 2011

i think i have an early type in my parts box.
let me know if you want it.i will sell off less than 1/2 price of a newie.just let me know if you are interested.
i've disconnected the electric start years ago,so it is no longer needed.
..weed..

DuaneB · May 23, 2011

So.. I put my old inner gear back in the bike with a new 2004+ sprague and 2004+ outer gear. It's now quite noisy, sounds a bit like loose valves. Is this normal if you use an older style inner gear with newer sprague and outer gear? e-start works perfect now hot or cold.

I also installed an 08 camshaft and a new IWIS camchain at the same time... I don't think these are causing any noise, but I did make a few changes all at the same time so I can't be 100% positive.

Taffy · May 23, 2011

Duane

you really need to check those teeth out with a fine toothcomb. any chunking, even a tiny one and the dented tooth will knock off the 'freewheel' inner gear teeth in no time.

We had a bloke here before Christmas who had a 2002 and when his had chunked and broke we fitted a new later freewheel and the whining was gone.

I know they still advertise the 2002 freewheel as being available still. it is defo the freewheel gear - 100%.

but I've yet to write down how it has been cured as it's hard to be scientific with the old engines as you don't know what has been replaced.

regards

Taffy

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