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02 tuono starter problem

ledlsed

ledlsed

Joined Jul 2008
17 Posts | 0+
New Zealand
Hi guys!!any help is much appreciated, i,ve owned my 2002 Tuono for about a year and half and its let me down for the first time!....the starter is not clicking in properly and makes a hell of a racket,still does it while trying to jump start it!i therefore think that its not a battery problem though and had a cheap battery in it that couldnt cut the mustard from new!,and it now has a new Yuasa in it only 5 weeks old. Its a hard thing on electrics starting a bike with the lights permanently on!!any 1 got any tricks for this?...i dont know about everybody elses bike but when i kill my bike the starter makes the same clunk once turned off...the same noise it makes on winding?it does this 90% of the time and the other times it will die as youd expect...quietly!!!not clunk...im not happy!!!...thanks guys,....new to this site and at the bottom of the world in New Zealand doesnt help much for gettin parts!:crazy
 
If you here a funny noise turn it off. The starter may be doing damage to what it drives. possible sprag gear. If your sure all wiring is good and all connections are tight (specially battery) than remove starter and check drive and driven gears.

Hope that helps.

Rob L.
 
it doesnt make noise while running,only on winding and it wont even engage for long enough to start it!,she's off the road now...and yes it sounds like a sprag clutch just like my last Triumph let me down...hope the motor doesnt have to come to bits to fix it like the Daytona did!!!
 
nice one VFR4lee !!!,i can see that something like the relay even with a mint battery could let it down in this fashion....Lucky i havent started stripping it down yet,will have to go to the sparkies though cause i hate wiring!!!is the relay under the seat? or stashed somewhere obscure?....thanks a shitload
 
thanks 'Bob',pulled solenoid and starter off last night to take in and get tested.I also heard back from the only Aprilia parts dealer in the country and he has priced the sprag parts for me;gear $920US dollars,housing $489US dollars,sprag bearing $1169US dollars and a gasket set at $75NZ dollars!!!!!!!!!i think thats going to be around a 1/3 of the price i paid for the whole bike.....feck that!!!,anyone got any clues where i can buy direct from overseas to save some money?.........will try the shortening of spring on bearing trick 1st to see if that remedies problem and then sell it bloody quick!
 
who is your local aprilia parts dealer?,i would rather try them!!...and UPS air freight to NZ
 
Aye carumba, not good matey

Hi, you are not alone. I'm in NZ and had my tuono do the same thing. Was definitely the sprag clutch and cost me $2600 all up. No way round it. Seems comon problem. After getting it fixed you need to (1) start with full "choke" and keep hands off anything else (no throttle, no clutch). If floods, give up and try again later. Continued cranking wears the sprag clutch until it fails (with all those nasty noises) especially if you get a misfire - bang/clunk (NOT good). Look at the thread below to help your starting system in the cold - this is the root of all evil by the sound of it. Mine just started to misbehave in the cold again and I am buggered if I am going to pay for another sprag clutch...

http://www.fourwheelforum.com/showthread.php?t=245

Off to get my soldering iron out now.

Good luck mate.
 
Highly entertaining. :lol

I find if I had it running, shut it off, go to restart and it fails to start right off (probably because I turned the throttle), the thing to do is crank the starter with the throttle WFO. It typically starts real quick then. :cheers
 
what part of NZ are you from SKD007?,just priced up Ducati sprag ex Australia for$395nz delivered,and gasket,housing and gear from RSVR in UK for $650 delivered...getting a hard grade bolt M22x1.5mm pitch lathed up square on its end to use as a puller,and **** that flywheel's on there tight...heated up wiv hot air gun for good 10- 15 mins but it needs rattle gunning off!!...$2600 is a nightmare!!,you would just about score a 2nd hand whole engine for that.
 
Sprag clutch nasty

Hey ho:
Just out of curiosity what sort of mileage where you seeing before the sprag let go.
I've got a 04 Tuono and my mate here has just cooked his 04 with 12000k's on her.

Cheers

Peter
 
Mine had about 24000 on the clock when the sprag, well, spragged. It always has had a bit of an Italian temperament and doesn't like starting in the cold. I need to do the solder fix (in my prev. thread) and also am planning on wiring a relay to the footstand so the lights are OFF when the stand is down, then can start the thing with lights off. I can't imagine why they want to have the poor battery crank that big lump with the headlight on. Silly. http://www.tuonozone.com/forums/images/smilies/crazy.gif

I have also found that a 14AH battery fits in under the seat (just) to replace the 12AH standard one. Soldering the voltage reg appears to solve the starting issue though.

Doesn't help with the crazy white wheels but. How in blazes did the designers come up with that idea??http://www.tuonozone.com/forums/images/smilies/dunno.gif
They need to be cleaned, and cleaned, and cleaned...http://www.tuonozone.com/forums/images/smilies/headbang.gif

OK, got to put on my LED indicators now. Anyone know of a flasher that works with LED's?
 
Mine has just clicked over 35,000km and im the 2nd owner.,i,ve got the sprag out now and bolt/puller worked mint with a little heat from a plumbers gas torch..only took a minute of heat and didnt even discolour the flywheel,rattle gun and it just popped off!!.nice to know that its torn down as far as it needs to go and now its waiting for parts time!!..:rolleyes
 

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I have had to replace my sprag clutch recently, the problem starts from not enough charge in your battery when starting,I didnt notice but it just takes a bit longer to start which starts to break up the sprag as it starts to spin back on its self over time it gets worse until the horrible noise starts.
The way forward is to use an optimiser which keeps your battery at optimum.
Its amazing how a fading battery can cost you so much, for me around £770 fitted.
I'm no machanic I just jump on and go as fast as I can, I hope this may save someone the cost. I wish someone had told me this..
 
Battery Tender is the way to go the bike has a ecm and lights and the memory in the computer will take a battery down quick and not to mention fuel injection and the fuel pump. The number one cause of most starter failure is a bad battery everything else has to work twice as hard and crank for sometimes twice as long. A battery tender will set you back almost a $100 bucks.
 
yeh, the optimiser I bought at trade £20, and your dead right when not charged its losing power constantly, and the Vtwin takes a big thump of power to turn over........
 
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