02 450 FSE issues

[wakeymatt]

I originally bought the bike knowing very little about it, almost expectantly i've had problem after problem but nothing large amounts of TLC shouldn't fix (I hope).
My intention was to supermoto it and i've almost completed that faze barring the brake.
First problem
Currently the E starter isn't engaging and the bugger seems impossible to kick with the amount of compression this thing seems to have. Bump starts are hilarious and a nightmare requiring two people and decent amount of dry road.
The battery seems fine and the bike used to start of the button but now it seems like the starter clutch isn't engaging.
I figure i'll take the alternator cover off and inspect the starter gears but i'm not entirely sure what i'm looking for if all the teeth are intact ?
Second problem
The bike when running would cut out randomly sometimes after 5 mins sometimes sooner or longer, then I would have trouble starting it as the battery seemed low. Perhaps alternator issues but before I could check the voltage the starter has faulted so haven't had time to check yet. Could it be electrical, perhaps a short, need to check spark plug and still but if anything else comes to mind i'm open to suggestions.

 

[Cruiser]

That hard to kick start sounds like it may need the valves adjusted.. If the intake are too tight it would be hard to kickstart.

 

[bergerhag]

Estart problems might be the sprag clutch behind the flywheel not gripping. Do a search on 'sprag' in the 4-stroke section, this has been discussed widely.

 

[wakeymatt]

Well I've found the problem was a snapped "STARTER PINION AXIS".
Question is do I need to replace the pinion or is it possible to just put new needles bearings into the old pinion ?
Also the case is damaged where the snapped pinion has floated around, it doesn't look to bad but a second opinion would be good !
@Cruiser
Yeah perhaps the valves are tight, is this something I can easily check perhaps, I've never done much work on 4t engines before. Perhaps this would explain the cutting out at idle also ?

 

[wakeymatt]

Got the replacement parts from Gasgas, with the alternator gasket is it worth using sealer on it ? It seems to have a strip of some sort of sealer on one side of it already.

 

[gasmonkey]

The case looks slightly damaged but is quite serviceable.Ime this is only part of the problem.Good luck.

 

[wakeymatt]

Holy crap, couldn't believe it !
Put it all together and guess what, still nothing engaging
Despite the completely sheered pinion the problem still persists, could this be the dreaded sprag clutch thingy ?

 

[wakeymatt]

Another issue i've noticed is when the bikes in neutral and the engines not running its hard to get the clutch to engage. If you roll the bike forwards and backwards a few times you hear a little beep and then in engages eventually. Can anybody explain why this is ?

 

[wakeymatt]

I've just been talking to a guy from http://www.behind-bars.co.uk/ on the advise of gasgas uk, very helpful indeed !
Half way across the country from me but defiantly going to get it booked in with them and sorted out.
In the UK it turns ou these are the only guys with the EFI software and as not many 02/03 bikes where ever sold and if they have never seen the bike (and they hadn't) then it will defiantly need plugging in and setting up with them.
Will probs get them to do the valves and stator clutch also while its with them, just need to win the lottery now

 

[Qui-gon]

Holy crap, couldn't believe it !
Put it all together and guess what, still nothing engaging
Despite the completely sheered pinion the problem still persists, could this be the dreaded sprag clutch thingy ?

I think you will need to pull the flywheel and check out the sprag clutch behind there as bergerhag suggested, The gear behind the flywheel which is just visible in your picture should turn one way and bind onto the crank when turned the other. If you do a search on here you should be able to find out some more information on it. As another poster has suggested your broken shaft may have been effect rather than cause.

 

[wakeymatt]

I think you will need to pull the flywheel and check out the sprag clutch behind there as bergerhag suggested, The gear behind the flywheel which is just visible in your picture should turn one way and bind onto the crank when turned the other. If you do a search on here you should be able to find out some more information on it. As another poster has suggested your broken shaft may have been effect rather than cause.

Yup the guy I was speaking to suggested the same thing about the broken shaft. Looking at the terrible history of these sprag clutches it would all makes sense (done plenty of reading on them). Not sure its something I want to live with when I get it sorted I will regrettably probably sell

 

[Qui-gon]

This may be of some interest if you haven't seen it already:

http://www.thumpertalk.com/topic/733750-drz-400-starter-clutch-gear/

 

[wakeymatt]

This may be of some interest if you haven't seen it already:

http://www.thumpertalk.com/topic/733750-drz-400-starter-clutch-gear/

Ah cheers fella, not thought of looking on thumper talk
Looks like a good fix but its an old thread and theirs not much info although I will look into it.

Cheers again !