This site may earn a commission from merchant affiliate links, including eBay, Amazon, and others.

Husaberg sprague cluth

D

derrickboltt

Joined May 2015
10 Posts | 0+
south africa eastern cape
I have recently rebuilt my 2008 Hus 450fe engine and included the double valve spring mod.(Ktm 450 spring kit)
I replaced the intermediate starter sprague freewheel bearing new but recently it started slipping . I suspect that the inner gear shaft that fits into the bearing that engages the clutch basket gear could be worn . I need to get the tolerance size for the inner shaft (Sprague gear) to ascertain the actual wear.
I have seen a few reports on the forum of sprague gears slipping ( You tube).
I could undercut the gear shaft and fit bearing grade sleeve if it is worn .?)
Could the inner bearing running diameter also be worn inside the gear housing.
Please comment and advise ...
Thank You... Derrick.
 
I would try adjusting the valves and ensuring the auto decomp is working properly before you get in to the other stuff.
 
Hi - Thanks for the advise .
Checked valves clearance and correct .( .12mm)
de-compressor pushes both exhaust valves down by 0.9mm BTDC.
Will check on the serf clip that hold in the bearing as it has slots in the case
of the bearing . Not sure if the points of the clip needs to go into these slots
of the bearing housing.
The inner gear rotates all the time and the outer gear stands still .
The outer gear only turns when u engage starter. The serf clip should provide
the friction to allow the bearing housing to rotate and then to engage the inner and outer gear via the tension exerted on by the spring. I have installed the serf clip in the slots of the bearing housing. ( Small slots in the housing) The points of the clips does not make contact with the bottom of the outer gear slot and then rotates freely in the outer housing. ( Must the clip not provide the friction to turn the bearing via the big gear to engage the inner.?)
Can anybody Please advise at where the clip must be inserted.
Thanks
Derrick
 
you're overthinking it Derrick, you need a stronger sprague spring. I do a kit to repair that bearing and also the starter clutch.

the spragues always slip after a rebuild or fresh oil etc (when you pour it in). so get it started on the kickstart and then try the button.

regards

Taffy
 
Thanks for the advise Taffy
I fitted a new sprague bearing and have also shortened the spring.
Bike was starting of after rebuild - Problem started a few months later about 10 running hours later . Slipping seems to be a lot less when motor is Hot .
No evidence of any wear on both gears inner and outer housings.
Can u advise on the kit you supply - Is it the bearing and both gears?
Is the modification kit any different to the original design..?
My manual does not show were the serf clip goes in bearing housing ..?
Can u please advise ..!- Thanks once again for your comments.
Regards
Derrick
 
go into my web shop and 100825 in a search.

the cirlip goes around all the flat slots in the bearing. It should be clear? then all the tongues that stick out through the slots will reach into the insdie wall of the sprague outer gear and they drop in a groove for it.

Taffy
 
Hus 450 sprague ..!

Thanks a lot Taffy for the circlip info .
I have micro measured the inner diameter and it is 39.63 mm .
It has +-.06mm wear in the centre of the journal contact area.( Slight hollow)
The size seems a little strange at 39.63.. Could be in inches..?
Would be great to get the actual tolerance size for the acceptable wear.

The wear on the mechanism will be greatest on this bearing journal as it
is turning a lot faster than the clutch gear speed all the time.
Apparently some of the older KTM 4 strokes had the same parts...?

We have rebuilt a Hus 650 with the mods for the upgraded crank bearings to correct for crank float and have had no problems with the sprague even though the motor has many more hours than my 450 ..
 
Thanks Taffy - The repair kit 100825 pics indicate a bearing spring which
Looks stronger and 2 by shims (seem to have saw tooth edge.?)
May I enquire were the shims and placed in the free wheel housing.
Thanks again for your response.!
Regards.
Derrick.
 
the spring is for the sprague and the shims are for the starter clutch. the photo is a small photo stretched and gives a strange result!

regards

Taffy
 
Hi Taffy :
We seem to have located the problem to the Outer gear housing .. The big Bearing running surface was worn and the inner support housing bearing worn.
We plan to replace all the engine housing bearing HK1080..?(Suspect.?)
We dont have the no of the inner bearing (10 by 13mm ) This is possible a common wearing bearing - Hence the bush replacement with oil groove .
We loaned a Hus 650 hub and did some changing out of the parts .
Had to remove the side cover about 10 times but is was worth the effort .
The torque clutch we overhauled by using a over normal tensile spring washer

The overhaul issue we found on the whole clutch is wear and tear on all the running surfaces and the bearings in the housings.
Changing the free wheel bearing only is a short term solution unless you can check the wear on both the running surfaces of the bearing on both gears.
The sizes and acceptable tolerance we cannot find any where .
Both the gears had a angular wear surface pattern . This could be due to the
worn support gear in the housing and the engine casings.
Thanks for your comments and guidance

Regards
Derrick. ( Out of Africa.)
 
From my modest experience the shorter spring is a very short-term fix.

Both the sprague and the outer housing should be replaced at approx 100 w/h and then the little red button works fine.

Also, all the chemistry around the torque limiter is useless.

M.
 
  • Like
Reactions: 1 person
derrickboltt said:
I have recently rebuilt my 2008 Hus 450fe engine and included the double valve spring mod.(Ktm 450 spring kit)
I replaced the intermediate starter sprague freewheel bearing new but recently it started slipping . I suspect that the inner gear shaft that fits into the bearing that engages the clutch basket gear could be worn . I need to get the tolerance size for the inner shaft (Sprague gear) to ascertain the actual wear.
I have seen a few reports on the forum of sprague gears slipping ( You tube).
I could undercut the gear shaft and fit bearing grade sleeve if it is worn .?)
Could the inner bearing running diameter also be worn inside the gear housing.
Please comment and advise ...
Thank You... Derrick.
Click to expand...

are you sure the one way clutch is slipping ?

as M has mentioned the torque limiter clutch is often dodgy

easy to fix though you just increase the preload on it with the big nut.

unit #21

088004011.gif
 
Derrick. Finally somebody I know on Husaberg.org :)

Hope you come right with your Husaberg...time for a 70 degree version now.

My offer for a ride in PE still stands, anytime.

Regards
Wayne Pettitt
 
Thanks Wayne:
My Huss has just been completely overhauled and going g8t.
Starter problem has now been finally solved!(Mechanism waxed..!)
Would enjoy a ride in P.E . My invite to the Wild coast still stands.

Regards
Derrick
 
Was in Mazeppa in January and again beginning May.

If the rest of the world knew about the Wild Coast we would be doing tours permanently. :)
 
Derrick,
Could you elaborate on the "mechanism waxed" to fix the starter issue?

thanks,
Greg
 
just get my kit and repair the pair. for goodness sake, even ebeneeza would find you lot tight!

Taffy
 
Sprague clutch Final response?

Hi Gents - In final response :
The understanding of a technical problem is the key to sorting it out..?
As a professional Tech Eng I have always been inspired by a challenge.
There is no monetary Value that can be attached to Knowledge....?
Greg - I think it may be wise to buy the Modified clutch kit...?
Please feel free to e.mail me as I would gladly assist.
My email is : [email protected]
Thanks ( Knowledge empowers the owner!).
 
Hi Wayne :
I have done the ride from Port St Johns to Kei Mouth .
4 days of amazing riding on the wild coast .
Cheers - Derrick .
 

Similar threads

ede
Swingarm bearing / bearing sleeve FE 501 (2002)
Replies
1
Views
1K
mars
mars
C
For Sale: 2008 FE 550 - Restored and Adventure-ready
Replies
0
Views
2K
canadius
C
C
For Sale 2008 FE 550 - Restored & Adventure-ready
Replies
0
Views
505
canadius
C
K
Husaberg again
Replies
1
Views
1K
Khristi
K
E
Service Repair Manual 2000 FE600E
Replies
11
Views
2K
Taffy
Taffy

Register CTA

Register on Husaberg Forum! This sidebar will go away, and you will see fewer ads.

Recent Discussions

Recent Discussions