Starter Failure

[Adam RodgersMember]

Ok so I put the mockers on myself when I said 7000k’s and no problems :unsure:

At about 7060 k’s on the Cells component of the B’day ride my starter locked up.

That is to say it stayed permanently engaged. The bike wouldn’t start as the starter motor kept spinning and didn’t allow enough speed for the engine to run.

The temporary solution was to remove the side cover and remove one of the intermediate gears. This left one gear spinning at about 4 times the engine speed. Not best practice however by keeping the revs as low as practical it got me back to camp.

The problem was the sprag clutch (KTM call it the “roller free wheel”) It is possible it was a back fire that caused it to break and lock up but regardless of the cause it locked up.

It took a bit to get it off the gear it runs on and I had to linish the running surface as there were some marks on it. Not a problem when you have the equipment to do it.

It will take me about 1/2 an hour to get it back together once the new sprag clutch arrives.

The photo of the sprag clutch is worse than when it was in the bike. As I said it took a bit to get it off the gear.

[attachment=4046]2013-07-15-205.jpg[/attachment]

The gear ready to linish
[attachment=4047]2013-07-15-206.jpg[/attachment]

[terryjhaynesMember]

Nice work there Adam,,,when do you expect the new sprag clutch to turn up?

[craig evansMember]

hey adam im just wondering why on earth your riding a kawi dressed in ktm clothing ? :laugh: :laugh:

you posted in kawasaki not ktm :laugh: :laugh:

[Adam RodgersMember]

teza h wrote:

Nice work there Adam,,,when do you expect the new sprag clutch to turn up?

Fingers crossed tomorrow (Friday)

[Adam RodgersMember]

wolfie wrote:

hey adam im just wondering why on earth your riding a kawi dressed in ktm clothing ? :laugh: :laugh:

you posted in kawasaki not ktm :laugh: :laugh:

I’m in denial :laugh:

I noticed that after it was submitted and couldn’t change it :whistle:

Adam.

[GregMember]

adam wrote:

wolfie wrote:

hey adam im just wondering why on earth your riding a kawi dressed in ktm clothing ? :laugh: :laugh:

you posted in kawasaki not ktm :laugh: :laugh:

I’m in denial :laugh:

I noticed that after it was submitted and couldn’t change it :whistle:

Adam.

Fixed mate not a problem you have enough anyway owning a KTM :laugh: :whistle:

Nice work btw good photos and explanation for all

TB

[Richard WMember]

I’m surprised they make such as chunky apparatus for a starter when low weight seems to be the norm and that it failed. The size of the rollers almost seems overkill..

[Adam RodgersMember]

Dickie wrote:

I’m surprised they make such as chunky apparatus for a starter when low weight seems to be the norm and that it failed. The size of the rollers almost seems overkill..

I’m guessing it could transmit a #%&* load more torque than it has too, however given where it has to fit it ends up being that size.

Once the motor is going it would simply become part of the flywheel mass.

I put the part in today and all good.

Will give it a good go on Sunday

Adam.

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