Malfunction electric start,OK Startmotor,OK Battery,NO START

AWelland · Oct 29, 2008

Hello and regards from Norway. Sorry if the forum post is'nt new

I have a 04 Husaberg FE 650. It runs fine and start well with the kick start, but not on the electric start. If the motor is warm the electric start works sometimes.

Startmotor: Yamaha R6(starter motor)

Battery: YTZ7S gel-cel

When i press the electric start motor i can hear that only the starter motor turns, and not the engine. I have checked the starter motor and have a new battery. The relay is also ok.
I have downloaded the 04 workshop manual and seen on the left side of the engine if there may be some components there that may be the problem.

Dont have a lot of experience in mechanics so if anyone have a suggestion of what the problem may be?

Can it be the starter drive/freeweel/freeweel hub?
(Husaberg 04 Repair manual page D22)

Sincearly AWelland

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jockular · Oct 30, 2008

Hi, i think your on the right track there, if the motor turns and the engine doesn't its probably the sprague clutch that sits in the larger of the two gears on the picture. You'll have to remove the clutch basket to get at the assymbly which is best done with a clutch holding tool, if your not to confident with the spanners it might be a job for a macomic. search the mechanical forum for previous threads, and theres bound to be something in the Doc about it.
Cheers,
Jockular.

Cheesehead · Oct 30, 2008

I had the same problem with my 03. Have a close look at wheel #1 on the picture, it consists of two gears which are connected by a bolt and nut. Normally there is no movement between these 2 gears. In case of a backfire, or something like that, the bolt will break (hard to see) and that's the end of the story. It's not a cheap part but easy to replace.
Good luck.

ned37 · Oct 30, 2008

the 04 450 came from the factory with a substandard torque limiter (item #1). not sure if the 650 was included in the problem, but wouldn't be surprised. the solution requires pulling it out (doesn't require clutch removal), disassembling it (use heat), adding a .015" shim, and reassembly. do a search on torque limiter (sparks) and see the doc.

AWelland · Nov 3, 2008

Thank you very much for the reply's.

Found a better picture of the electric start system.

Taffy · Nov 3, 2008

if you send me the #1 and #2 i will repair them for you. that's all that's wrong with your bike. i've PM'd you.

regards

Taffy

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Malfunction electric start,OK Startmotor,OK Battery,NO START

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