For those KTM owners with starter motor problems

[RoyMember]

From what I have heard it is a fairly common problem on the 08 and 09 2T models. The first time mine stopped working after 12 months. This was not good considering my right leg had withered away from lack of use over the past five years. It also meant some lazy riding habits had to be rectified fast as I couldn’t just press the button after a stall and get going before the bike had even stopped moving.

Anyway, the first time it happened I was a bit unsure about doing it myself and took it to the auto electrician. Bad news is a new one is in the order of $800. Good news is new bushes and a bit of labour is $130. The bushes had to be purchased from the bike shop but I am not sure if it was a ktm shop or not. The bushes are not listed in my ktm spare parts manual but haven’t actually asked the shop myself yet.

Anyway it happened again on the weekend. Did the usual and checked the battery (with and without load)and the voltage at the starter motor. All 12.6V plus. Not a good sign. Finally had to man up and learn how to do this myself. Pulled it apart. Very simple in the end. Undo 2 bolts and the whole thing only pulls apart into about 5 bits and three of those are the segments of the outside covers. All looked okay to me, not much crap in there but the contact surface on the armature seemed a bit black so I hit them with the wire brush and got them shiny.

Then the fun began. I tried to hold the brushes in with my fingers whilst sliding the armature back into place before the spring loaded brushes popped out. This was starting to look like a job that could only be completed by a four handed ambidextrous yoga practising monk and I was almost at the “I have to throw a hammer stage” when I figured there has got to be an easier way.

The trick is to take out the plastic part in the end of the starter motor that holds the brushes and put it and the brushes on the armature before sliding the whole assembly back into the outer cover and doing up the two screws that hold the plastic part. The positive terminal that bolts to the cover needs to be undone to be able to remove the positive brush from the cover housing.

I apologise for the lack of photos. I did have good intentions but something came up when I was only half way through and I had to rush and forgot the photos (but don’t worry there will be a next time going on the history so far).

The whole thing suddenly become reasonably easy after I tried this technique.

[RoyMember]

Put it back on the bike and all fired up first go. Very relieved. I think part of the problem is the unit doesn’t seal very well and moisture gets in and causes the contacts to tarnish up. The two bolts holding the unit together seemed a bit loose so I have tightened them this time and will keep an eye on them to make sure they don’t vibrate loose and see if this helps. Not real keen on having to do this every 3-6 months.

IS the wire brush okay to use or is it too harsh for the soft metal contacts. Didn’t seem to mark anything so I was hoping it was okay.

Anyway the good news for any ktm owners out there who are sitting on a stuffed starter motor is that it can be fixed yourself for around $20 and a bit of your time. It’s not that hard and there’s only a few bits so it’s easy to remember which order they came out.

[GregMember]

Great write up Bundy awesome DIY

TB

[jamieMember]

Nice work,nothing like a cheap repeatable fix. Can you improve on the water proofing or spray clean/dry it after any wet weather?

[RoyMember]

I thought about putting some silastic on the two joins in the outer cover but decided against it as I thought it would only make things harder next time. There is a rubber seal in each join sort of like a square o-ring. The biggest hassle is the starter motor is behind a plastic cover for protection and the cover is held on by four bolts (two of which are also used to hold the side case cover on) so it is hard/time consuming to get to regularly. I have been half tempted to take the cover off as I reckon all it does is trap dirt and moisture but knowing my luck a big rock would take out the starter.

[jamieMember]

Searched for a pic so i could get the drift of things and came accross some tips they suggested,re tapping the 6mm case holes to improve earthing,and shimming the gears to reduce backlash,and sealing it with a breather hose and running oil on the gears. Ill try and link it.

[jamieMember]

http://support.ktm-parts.com/entries/252200-ktm-300-xc-xc-w-exc-bendix-damage

[RoyMember]

Thanks for the link twobanger. I knew about most of those options (not the thread cutting but). It is like there are two seperate issues. The starter itself and the bendix gear issues. I know all the bendix issues take load of the starter which in itself should help the starter. I have often wondered about the earthing issue. It doesn’t excite me that much earthing back through the motor and frame to the battery. I was actually thinking about running an extra earth wire from the startor to the battery. I have checked my bendix and although I don’t run it in an oil bath I have removed all the ktm grease and used good quality stuff instead.

Just had a thought whilst thinking about the earth issue. If you put loctite on those bolts does that mean they won’t be as good for earthing. I don’t know but just thought of it so thought I would put it out there for comment. I didn’t loctite them this time anyway but I probably would have in the past.

[jamieMember]

no probs Bundyroy,yeah i like loctite on stuff so the earth duplicate could be the go.

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