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[Michael]

Hi All

First posting, so I am sorry if I have started a thread where one wasn't necessary. I have a 2008 Bullet EFI Electra 500 (an early one) with the UCE engine. My old bullet (lean burn) suffered from a faulty sprag clutch, and I understand that this was a common failing on the older models.

I have recently had some starting issues when using the electric start, kick start is still fine. When I try the electric start the motor often doesn't catch for a while, or at least catch 'properly'. Yesterday morning I had this issue and I felt some compression through the exhaust pipe as I tried to turn the motor over, but no real catching. I also hear a loud, unnerving 'clunk' when the starter doesn't catch properly (it often then catches after the clunk). Also, I once had a big backfire - clunk - cut out when throttling down a few months ago. The clunking has become more frequent since.

Does this sound like a failing sprag clutch? Is it still an issue in the EFI models? And is it worth me doing the repair at home (never having carried out a 'spragectomy' before).

Any advice from those in the know would be great...

[rog]

Michael, it's not just the sprag clutch that can fail, sometimes you lose a teeth or two from the idler or driven gears between the starter motoer and sprag clutch. These can make a lot of noise without preventing a start. Replacing these and/or the sprag clutch isn't too difficult but can require some special tools to remove the clutch and alternator rotor. Removing the sprag clutch and gears will get rid of any nasty noises and leave you with a perfectly good kick-start bike, but if you decide to replace the damaged parts I'd also fit one of Hitchcock's stepped keys when replacing the alternator rotor. If you have read their catalogue you'll know that many (if not most) Electras have their non-checkable/non adjustable timing set too advanced, which contributes to kickbacks and starter motor system damage.

[Frank]

Rog, are you talking about the Electra X or Electra EFI here? The rotor keys were Electra X and I'm not sure if they are applicable to Michael's EFI.

[Michael]

Hi Rog, thanks for your reply. I might be wrong, but I think Frank is right in thinking that your comments relate to the Electra X. The alternator stator and rotor in the EFI are in the right side engine casing, and the clutch, sprag and starter are in the left side casing. I assume that you comments regarding noises coming from the gears would still apply though? Can/should I still run the bike on kickstart if the sprag or gears are potentially weak/gone?

If anyone has any idea about other potential faults (if any) that these symptoms could reflect then it would be great to hear about them.

[rog]

Michael, yes, you and Frank are right. Too much wine before logging on last night I suspect. As far as I'm aware the sprag hasn't become a major issue with the EFI models, but I guess it could sufferif you've had some backfires. Is your battery up to scratch, as a dodgey battery could cause the the bike to be reluctant to start (all the 'juice' going to the starter motor and not enough for a strong spark. Perhaps the delay in starting then upsets the fuelling leading to the backfire?

[Michael]

Well, I had a wee chat with a local mechanic and he suggested that it could be the sprag. The dealer called for a part price and I was a little staggered by what came back. If anyone has replaced an EFI sprag clutch yet it would be interesting to hear the ball-park figure for the parts: the rough price for the sprag and/or the whole assembly (bearings, gears and so on). The parts listed by the hosts here don't make it clear if they are EFI or leanburn parts.

If the quote from the dealer for the part is correct (I can't believe it, more than double and almost triple what I was expecting) then I am going to have to do it myself. Anything to watch out for?

I guess the wife's Christmas present will suffer.

[Norm]

Michael,
Doesn't help much but it isn't a common problem with these unlike the previous models. Sorry,never pulled on to bits so I can't help

[Frank]

Michael, sounds like you need a parts book and workshop manual. Not cheap in themselves, but at least you will be able to see what you are up against and be able to identify and price the correct parts.

[rog]

Michael, from the diagrams in the workshop manual, changing the sprag clutch should be much easier on the EFI than on older bikes like the leanburn Electra. You don't have to remove an inner chaincase for a start. I would have thought it very straightforward to whip off the EFI chaincase to see what's happened before you part with any cash. Watsonians certainly sold individual sprag clutches for the leanburn, so hopefully they do the same for the EFI as there may not be any damage to the other components. However, whatever repair is necessary the priority must be to find out what caused it?

Rog

[Michael]

Cheers Rog. I will probably buy a gasket and have a look over my Christmas hols. *If* it is a bad sprag then I think I know a few potential causes, but any advice would be useful. I believe early EFIs may share the same weak sprag as the old leanburns, newer EFIs apparently have a more robust sprag - and apparently the sprag fails due to backfires or a sticky decompressor? The EFIs have an auto-decompressor which has been known to stick a little in the open position, allowing fuel to get into the exhaust, so maybe looking at that might be in order. What else other than a weak spark or dodgy decompressor may cause a backfire?

The battery is good (new gel one fitted in the spring) and charging system seems OK (not perfect, a little low on AC volts at high RPM, but not by much) so I assume the spark is generally strong enough. I clean the plug quite regularly, it blackens quickly but I have never been good at telling a good plug from a bad one.