Torque Limiter "disc spring" or "spring washer" needed!

My FE 650 starter was slipping. It came time to dig into the bike and get it fixed. I went straight for the Torque Limiter, planning to shim it. To my surprise the "disc spring" or "spring washer" had a section broken. Now the disc spring has like a piece of a pie cut out of it. This is obviously my problem. My question is where can i locate/buy the spring washer/disc spring. from my measurements it is 22mm OD X 11mm ID X 1.2ish mm thick with a slight convex shape to it. I dont want to have to buy a whole new torque limiter since this simple washer is my problem. I have looked in parts books and online but nothing shows the part # for just the spring washer. I am located in Houston TX USA. Please help!

Or if you know a simple aftermarket washer that will work.

Thanks all for reading the post!

Thanks for the advice! So far i have found the booger called "spring washer" "disc spring" or "belleville washer". There are tons and tons of washers made of many different materials. Does anyone know the specific material? also the load when flat in preferably lbs. I am assuming the belleville washer is made of carbon steel but dont know what strength of a spring i need to get. different thickness/styles offer different load capabilities. Any insight to the load strengh (load when flattens) needed for the torque limiter?

Thanks,

Berger,

I have been talking with Taffy, thanks for letting me know he sells what i need. But I am still interested in more of the compound requirements and load requirements of the disc spring/belleville washer/spring washer. I am hoping to find one locally. I have found some made of Steel, Carbon Steel, and Stainless steel, vanadium and other alloys. The flattening load capabilites range from 205, 438, 994, 12xx, 14xx lbs. Anyone know what the Torque Limiter requires?

Thanks!

I was hoping someone has already figured out thru trial and error, pure luck, or just knows the actual load requirements. It sounds like Taffy has already done the trial and error in figuring out what belleville washer load requirement works. I think it would be fantastic if Taffy or anyone else who knows this information can post it on this site for everyone to know, since this seems to be such a common problem. Ill ask Taffy and get back to you all. If no answer will either order thru Taffy or do trial and error myself, then let everyone know. Thanks for everyones input! I hope to get this figured out for everyones benefit!

As for the break point for the torque limiter, according to the Owners doc the limiter should break free at 12LB/10Nm. I know others like that a bit higher.

I knew I had read somewhere people like the torqe limiter to break away somewhere around 25lbs. maybe we should update the Owners Doc? 30lbs will be what i aim for! Thanks Taffy for the info.

In my case the washer actually broke, i know most of others husabergers problems is the washer loses is strength and thats why we often have to shim them... to put some umfff back into the washer.

Email from Taffy: "When I see it, it’s always flat. It even comes out flat half the time and not cupped at all. It’s a case of cruching them up quite frankly. Officially they take 30lb to break when new and that’s what I aim for."

If you actually look at the washer, it has a slight conical shape to it. It may look flat but its not and its not supposed to be. If it is flat, you may have overtightened yours. The "conical" shape is designed to put pressure on the plates between the two gears. That is exactly what a Belleville spring washer (spring washer, disc spring) does. If yours is flat when take it apart or breaks too early, then that is why folks put shims to compensate for the belleville washer that has lost its shape and strength... there is a "shoulder" on the center shaft of part of the limiter that stops you from tightening and leaving just enought gap for the belleville washer. Put a shim in it and that will essentially fill the gap. Also one can file down (very carefully) the shoulder (closest to 17mm nut side, not the threads!) of the treaded center shaft to accomplish the same outcome with out a shim or new washer. My washer is broke so i am forced to buy a new one. I will post pictures when I get home. But for now you can look on the Owners doc under "poor starting" about 1/4 down the page under the "starter freewheel" section, there is a picture of the Torque Limiter taken apart... notice in the two pictures the washer. In one picture the washer has wear on the outside circumfrance surface, in the other its on the inside circumfrance surface.... proving it is conical. Visit http://www.internationalsprings.com/bel ... washer.htm for some info about belleville washers and a side drawing of one.

It looks like i may have to just order a bunch of different ones and see which one give us what we need!

I have ordered 6 different belleville disc spring washers. Will keep everyone posted which one give me what we need... approx 30lbs.

Here is what I have found. All washers I ordered are made of High Carbon Steel. I also cant guarantee the accuracy of my torque wrench but this is what results I got.

The following Belleville Spring washers sizes break away around 10 ft/lbs: 22.5mmX11.2x1.25 (which is closest in size to the stock washer) and .875"x.442"x.045".

Acceptable results:
.875"x.460"x.059" breaks away at 18 ft/lbs
22.5mmX11.2mmX1.25 + a .875"x.442"x.031". breaks away @ 21 ft/lbs the .31 with the .045 gives same results.
.937"x.453"x.070" breaks away at 24 ft/lbs

I did not test the combination of a .875"x.460"x.059" + .875"x.442"x.031" which i would assume breaks away closer to 30 ft/lbs.

I am going to go with the 24 ft/lbs and will let you know if I ever have any issues.

I have a handful of each of these sizes so if anyone needs a washer let me know and ill send one your way. In return i ask you to donate to this site even if its a few bucks.

So the bike is all back together and could not be happier with how easily it starts up. Cold the bike will start up after 2-3 turns of the motor. Its nearly instantaneous. Like I posted earlier i went with the Carbon Steel belleville spring washer .937"x.453"x.070" which breaks away at 24 ft/lbs. Thanks for everyone's help! Also i have 6-12 of each of the washers mentioned above so if anyone needs one let me know.