Broken tooth on clutch basket

Daniel_hoy · Aug 7, 2011

The engine started to make new sounds today so I took of the clutch cover to check if the crank nut was loose again.
The nut was ok this time but there is one tooth missing on the clutch basket. Is this a normal problem? And WHY does this happen? Will one missing tooth make a loud noise? Or is it maybe something else that is wrong?

FS650 186,0 hours. Normal riding no racing.

DuaneB · Aug 8, 2011

Most important first question... did you find the broken tooth yet?

I've broken teeth on the inner sprague gear a couple of times but never the clutch basket, however that may just be stupid luck. Both times I broke a tooth it was when I stalled the bike and the engine kicked over backwards quite hard. I have "tweaked" my torque limiter on the starter and my suspicion is that I have it too tight so it won't slip when this type of stall occurs. Have you ever adjusted the shims on your torque limiter?

Also, what year is your bike? I happen to have a brand new clutch basket on the shelf for a 2004-ish model... I wanted to retrofit it to mine, but can't because of the gear pitches.

Daniel_hoy · Aug 8, 2011

DuaneB said:
Most important first question... did you find the broken tooth yet?

It fell out when I took of the clutch cover. So I have all missing parts. Nothing on the magnet.
But the question is, did it just break or is there something else in the engine causing it?

DuaneB said:
I've broken teeth on the inner sprague gear a couple of times but never the clutch basket, however that may just be stupid luck. Both times I broke a tooth it was when I stalled the bike and the engine kicked over backwards quite hard. I have "tweaked" my torque limiter on the starter and my suspicion is that I have it too tight so it won't slip when this type of stall occurs. Have you ever adjusted the shims on your torque limiter?

No never adjusted it.

DuaneB said:
Also, what year is your bike? I happen to have a brand new clutch basket on the shelf for a 2004-ish model... I wanted to retrofit it to mine, but can't because of the gear pitches.

2008. Have alredy ordered a new cluth basket and gaskets ++

Taffy · Aug 8, 2011

Hello Daniel

I'm sure you have done this but please check that you have all the teeth on the freewheel gear that comes out the middle of the sprague. this can get very stressed due to the longer teeth! I would even go as far as to say that if you ran the bike like that for an hour or two: that you need to buy the freewheel gear just for safety sake?

regards

Taffy

Daniel_hoy · Aug 8, 2011

Taffy said:
I'm sure you have done this but please check that you have all the teeth on the freewheel gear that comes out the middle of the sprague. this can get very stressed due to the longer teeth! I would even go as far as to say that if you ran the bike like that for an hour or two: that you need to buy the freewheel gear just for safety sake?

Do you mean the small one over clutch? First time I open up bike engine and I don`t know the name on everything.

I think the engine only ran 1-2 minutes after it happened.

Taffy · Aug 9, 2011

yes the one over the clutch. If you didn't try to start the bike (and I bet you didn't!) it would have stripped the teeth off like candles.

regards

Taffy

tholen · Aug 9, 2011

This happened to my -05 FS 650 two years ago too.Nothing else destroyed.I just switched the clutchbasket and have used it about 40 hours after that with no problem.

Daniel_hoy · Aug 23, 2011

Changed the clutch basket yesterday. Everything looks fine.

HH nut on clutch drive M18x1,5 Loctite 243 + 120 Nm - Is this the nut on the clutch basket?

And is 130 Nm and loctite 2701 the "new" torque on the crankshaft nut? Just want to check it when it`s easy to do. I don`t want any problems with that one again.

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