Broken E/Start Gear

Ozrider:

In 200,1 when the new motor design was introduced, virtually all of the e-start models suffered from a faulty slip clutch gear causing the damage you have described. All of the bikes in the states were covered under a warranty program that replaced that gear. Here is what I wrote about it in "The Doc":

Starter Gear Warranty Issue Early 2001
The very first 2001 engines produced came with a very weak electric start Slip Clutch Gear Wheel. During e-starting, if the engine backfires, there is a good chance the gear will break and sometimes damage the Free Wheel Outer Part. If the engine stalls it can try to run backwards for a moment breaking the starter gear. A updated starter gear was produced and covered under a warranty program. Most early 2001 models were updated at the dealership level or by the motorcycle owner as they all would eventually break. The updated part number 250 283-01 supercedes the retired faulty part number. Reports of the updated warranty part breaking are almost nonexistant. There are potentially a few bikes out there that did not receive the update in the U.S. as the importer discontinued its affiliation with Husaberg during this period leaving a void for quite some time. Cryogenically treating the gear will add an extra margin of strength.

I just wonder if yours is an 01 or maybe an early 02 that never got the update. You stated that you replaced the free wheel assembly. Were used parts procured rather than new?

I believe you will find there was a batch of faulty gears that also found their way into the 05 KTMs and Husabergs.

Have never heard issues with 04 or 06s having problems- only seems to be a QC problem on an isolated batch.

ozrider said:

Can anyone tell me whether I could expect better reliability with the 550 starter setups or do they self destruct if subjected to an engine kickback as well??
Mick

Click to expand...

In 2004 the name of the part was changed to, Gear Wheel Torque Limiter, and is designated as a new part in the parts book. As Ausberg stated there were issues again in 05. A quick VIN # check by your dealer can tell if you have an affected 05. My 05 FE450 was not affected.

BOSS knows the amount of torque required to check the slip function of the gear. Before you replace the gear again with a new one be sure it is the updated part number and secure it in a vise and make sure it slips when the critical amount of torque (using a torque wrench) is applied.

So to answer your question regarding newer models, the 2004's and up essentially have this issue ironed out.