Torque Limiter

gwp58 · Oct 25, 2010

Has anyone had issues with 09 or later Torque Limiter .
I have ruled out all other possible causes of my starter stalling and thus not starting my 450.
I have removed the limiter and played with it a bit in the vise ,it seems to work but I dont know the limiting value so I cant test it properly .
Anyone help?

Graeme

any info at all ?

eyspy · Oct 25, 2010

Yes.

Replaced under warranty and all is good now. Initially they replaced the cam tensioner as this gives identical problems when playing up.
They just put a brand new torque limiter in and never had a starting problem since.

Taffy · Oct 25, 2010

under 15 pounds they have had it on the earlier bikes and you need to shim them back to 25-30 pounds.

regards

Taffy

gwp58 · Oct 25, 2010

Thanks Taffy .Eyspy and Berger .I pulled the case off and the clutch and observed the limiter slipping ,from the outside it sounds like the starter is stalling but its quite the opposite .
The starter is spinning away and the torque limiting gear is slipping ,as mine was without oil at this stage it started to grab and work properly ,I wish I had done this 2 days ago .

Conclusion .
If you have hot start problems and your starter makes a squarking sound and vibrates when you touch it ,
go straight for the torque limiter and save yourself a day or so pulling everything apart and testing cables,relays etc.

I have had hot start problems for 6 months ,it finally stopped starting at all last weekend .
the bike has done 100 hours over 4000 km and when it starts it is awesome no other issues at all.

$200 bucks for a new limiter ,I would have paid way more last Saturday out in the forest .

Graeme

Taffy · Oct 25, 2010

just shim it up mate!

dismantle it as per the doc and then shim it up.

regards

Taffy

gwp58 · Oct 26, 2010

I dismantled the torque limiter ,it just screws apart .It obviously has been assembled with loctite .
All the parts look ok.I now have to find the correct torque setting I can test the new limiter I ordered and get the torque value .I have rigged up a torque wrench with an 11/8 socket it fits the small gear perfectly and while holding the larger gear in the vise with soft jaws of course i can test the torque value quite easily .
I suppose I could just wind it up till it works (I have done this already) though i dont know if there are any other issues if they are set too tight ,like shearing the starter shaft or stripping gears etc.

I'm getting a bit excited it has never started properly since i've had it . now I may even be able to start in gear, won't that be something .

Regards Graeme

Taffy I cant see any need for shims in the 09 limiter the nut wasn't done up all the way I could get about half a turn out of it .
i dont think the nut had come loose the static plate has a square edge to stop it rotating thus not being able to work the nut loose .

Taffy · Oct 26, 2010

i seem to have been on about the wrong bike fella! I owe you an apology.

I hope it's the same as the 2001-2008s but you'll have to be aware.

regards

Taffy

gwp58 · Oct 27, 2010

The new limiter came today ,i put it in the vise and tested the torque setting 20 ft pounds.
torqued up the old one with some new loctite and it works like a charm .
It starts cold in gear and everything like a new one .

Graeme

Torque Limiter

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