스크랩 KTM300XCW-e의 셀스타트 관리는?

[드리프트킴]

국내에 셀이 달린 2-스트로크 KTM300이 두대 들어와 있습니다.

스타터모터가 '08년부터 달려 나오기 시작했는데, 일부에서 완전방수가 되지 않아 고압세차시 발전기카바속으로 물도 들어가는 모양입니다. 

4-싸이클에서는 모터부분만 건조한 상태에서 작동되고, 기어부분은 엔진오일이 뿜어져 기름칠이 됩니다만, 2-스트로크 KTM300에서는 기어부분까지도 마른 상황에서 작동됩니다.

고로 정기적으로 그리스칠을 해주지 않으면 그리스가 날아가고 말라버려 이쪽저쪽 마모되고, 쪼금씩 축이 이동되고, 그러면 기어이빨들이 꽉 맞지 않게되고, 종당에는 모터만 돌고 크랭크는 돌지 않게 되는 수가 있답니다.

기어이빨도 깨질 수 있는거구...

사용자매뉴얼에 그 부분 그리스 칠 하라는 이야기가 있다는 것 같은데,,, 그런 거는 잘 안보고, 봐도 무시해버리기 십상이죠...

스타트모터부터 크랭크축을 돌리기 위해서는 여러개의 기어를 돌려야 동력이 전달되는데, 그중 카바쪽에 의지하고 있는 기어축쪽에 이런 현상의 가능성이 큰 모양입니다.

아래 링크에 들어가보면 뻘건 그리스칠을 잔뜩 해 놓았는데, 어느부분이 취약한 지 파악할 수 있을 겁니다.

http://www.thumpertalk.com/forum/showthread.php?t=597295

답글중에 엉뚱한 이야기도 나옵니다만,

스타트 모터든 그 동력을 이어주는 기어축들이건, 기어 이빨이건간에 가끔은 닦고, 조이고, 기름치자는 군대식 정비지침이 필요한 것 같습니다.

기름은 방수가 되는 좋은 그리스가 좋다니까 현실에 맞는 거를 구해서 자주 칠해 주세요~~~

아래 covacica  라는 놈은 80시간 주행에 스타트 모터 두개 해 먹고 돈이 아까운지 스타트모터관련 부품을 다 떼어 버려고 막았답니다.     처음에는 멋모르고 걍 사용한 모양이고, 두번째 모터로 바꾼다음에는 10시간에 한번씩 기름칠을 해 줬다는데도 고장났던 모양입니다.

아래 dirty666  라는 놈은 4번 타고 스타터모터는 물론이고 그 근방 부품들이 아작나서, KTM딜러한테 이것 저것 따지고...

또하나의 스타트모터관련 고장은 시동이 걸려도 스타크모터와의 동력전달이 끊어지지 않아 엔진의 힘으로 스타트모터가 돌면서 고장을 일으키는 건데, 맨 아래 줄 안맞게 퍼 온 부분이 그런 내용입니다.

바이크 출고시에 발라진 끈끈한 그리스를 다른 그리스로 바꿔 발라주고, 벤딕스 스프링을 바꿔줘야 한다는 둥 하는데, 내 바이크도 아니고 하니까 ... 연구를 마칩니당^^.

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panton	Posted: Sep 19 2008, 04:53 PM
KTMTalk Member Posts: 11 toronto, ON Member No.: 30368 Joined: 31-December 04	I have an '08 300 xcw-e with about 30 hours. At 15 hrs I noticed the e-start was not functioning properly - engine would turn over a bit but would not ignite - continued use of the e-start button creates a "clicking" sound which I think is coming from the e-start relay. I spoke to the dealer and he suggested lubricating the gears in the starter motor - apparently water can leak through the cover during pressure spray. Both the battery and the e-start relay fuse are good. Any suggestions would be appreciated. Thanks Peter

emelvin	Posted: Sep 19 2008, 05:20 PM
Bench Racer Posts: 151 Fresno, CA Member No.: 40062 Joined: 22-July 05	It seams that a lot of people regrease it regularly. KTM uses white grease on the starter internals; I found most of it on the case sides when I regreased mine. Just make sure you do not get much grease into the #55140026000 BENDIX. When I did mine the first time, I put grease into it and it would not ratchet. It needs to expand when you hit the starter button to spin the motor. -------------------- Earl 2008 KTM 250XC-We: Recluse Pro Clutch, Guts step seat, TireBall's, FMF Q Stealth, Trail Tech Stator, Trail Tech Extreme HID Light, IMS 3.7 gas tank, EBC 280mm Front Brake, Lot's of misc. INVESTED - $$,$$$.$$ WOW 2006 Kawasaki ZX-6R (gone) 2005 Suzuki RM-Z450 (for sale) 2005 KTM 525exc--plated (Gone- Traded for RM-Z450) 2004 SCORPA SY-250 2000 KLX 300r 1999 Harley 883 Sportster 1968 Bultaco 250 Metrella

panton	Posted: Sep 19 2008, 05:38 PM
KTMTalk Member Posts: 11 toronto, ON Member No.: 30368 Joined: 31-December 04	Thanks Earl. What is the#55140026000 BENDIX?

emelvin	Posted: Sep 19 2008, 06:32 PM
Bench Racer Posts: 151 Fresno, CA Member No.: 40062 Joined: 22-July 05	It is from the 3CM083685HEN_MOTOR_250_XC-WE_2008 down loadable pdf found on many ktm parts suppliers web sites. I think most people also get the manual as a paper copy with the purchase of the bike. It was on page 20 of my manual, Item #2. I only have the 250xc-w and 300 xc manuals, the xc does not have an electric starter. But I think 250 and 300 use the same starter. If not someone here will correct me. A link to the free manual's is: http://www.ktmcycles.com/manuals/2008/ I do not see a manual for the 300 xc-w. Hope this helps. -------------------- Earl 2008 KTM 250XC-We: Recluse Pro Clutch, Guts step seat, TireBall's, FMF Q Stealth, Trail Tech Stator, Trail Tech Extreme HID Light, IMS 3.7 gas tank, EBC 280mm Front Brake, Lot's of misc. INVESTED - $$,$$$.$$ WOW 2006 Kawasaki ZX-6R (gone) 2005 Suzuki RM-Z450 (for sale) 2005 KTM 525exc--plated (Gone- Traded for RM-Z450) 2004 SCORPA SY-250 2000 KLX 300r 1999 Harley 883 Sportster 1968 Bultaco 250 Metrella

emelvin	Posted: Sep 19 2008, 06:46 PM
Bench Racer Posts: 151 Fresno, CA Member No.: 40062 Joined: 22-July 05	As to what a Bendix is "When the ignition switch is placed in the start position the starter spins at a high rate of speed, centrifugal force moves the spring loaded bendix forward and engages the fly wheel teeth which turns the engine to initiate the start. Usually the first indication of a malfunction is when you attempt to start the engine, the starter spins with no load and sounds like an electric motor running (which it is)." from unknown source This is what happened to me with too much lubricant; actually it was probably because the grease was too good. -------------------- Earl 2008 KTM 250XC-We: Recluse Pro Clutch, Guts step seat, TireBall's, FMF Q Stealth, Trail Tech Stator, Trail Tech Extreme HID Light, IMS 3.7 gas tank, EBC 280mm Front Brake, Lot's of misc. INVESTED - $$,$$$.$$ WOW 2006 Kawasaki ZX-6R (gone) 2005 Suzuki RM-Z450 (for sale) 2005 KTM 525exc--plated (Gone- Traded for RM-Z450) 2004 SCORPA SY-250 2000 KLX 300r 1999 Harley 883 Sportster 1968 Bultaco 250 Metrella

gpilot	Posted: Sep 20 2008, 09:49 PM
KTMTalk Member Posts: 15 Las Vegas, Member No.: 89388 Joined: 15-March 08	I had the same thing happen to mine last month, the starter was bad. I had it re-built by a local auto starter shop, 65.00 with a one year warranty. If the clicking you are hearing is at the relay by the battery, check to see if it is passing 12 volts to the starter. If it is then your starter is probably bad. Also, I noticed that where the bendix mates to the ignition cover that it was worn out causing the bendix to have a lot of slop so I think that it was not en-gaging or disengaging properly and that is what I think caused my starter to fail. Good Luck

panton	Posted: Sep 21 2008, 12:18 PM
KTMTalk Member Posts: 11 toronto, ON Member No.: 30368 Joined: 31-December 04	Guys, thanks again for the advice. One additional question, the KTM Tecnical Bulletin states the following: •Grease all pivot points and gears with a long term grease like KTM grease (p.n. T625) or Molykote? 33 grease. The T625 KTM grease and Molykote? 33 might already be available in your workshop as it is included in the WP special tool kit. To be clear, should I apply grease to "ALL gears with teeth" Peter

emelvin	Posted: Sep 21 2008, 01:47 PM
Bench Racer Posts: 151 Fresno, CA Member No.: 40062 Joined: 22-July 05	I cleaned the grease from the case sides and then applied it to all gears. I used Bel-Ray Waterproof Grease. -------------------- Earl 2008 KTM 250XC-We: Recluse Pro Clutch, Guts step seat, TireBall's, FMF Q Stealth, Trail Tech Stator, Trail Tech Extreme HID Light, IMS 3.7 gas tank, EBC 280mm Front Brake, Lot's of misc. INVESTED - $$,$$$.$$ WOW 2006 Kawasaki ZX-6R (gone) 2005 Suzuki RM-Z450 (for sale) 2005 KTM 525exc--plated (Gone- Traded for RM-Z450) 2004 SCORPA SY-250 2000 KLX 300r 1999 Harley 883 Sportster 1968 Bultaco 250 Metrella

jeb	Posted: Sep 21 2008, 03:42 PM
Charter Member Posts: 43155 Rogers, AR Member No.: 33 Joined: 11-January 02	Do some searching in this forum on this. I have the ktm bulletin on servicing it at my 'bulletin' link below. -------------------- John B jejb@att.net Jeb's KTM picture pages Jeb's KTM bulletin, how-to's and misc page Razorback Riders Club Website Golden Eagles Club Website Life Member Blue Ribbon Coalition Life Member AMA 08 250XCWE, 07 200XC, 04 250EXC 2t (06 frame), 06 300XC-W (sold 4/07), 03 450EXC (sold 9/05), 01 400EXC (gone), 99 250EXC (gone), 99 200EXC, 98 125EXC (Darling wife's), 98 380MXC (long gone)

bowhunter	Posted: Sep 21 2008, 07:13 PM
Pit Rider Posts: 337 Bozeman, MT Member No.: 82730 Joined: 2-November 07	I have cleaned and lightly greased my e-starter twice now and since clocking 90 hrs on my 300. These starters are definetly not dust proof nor water proof so stay on it. What I have noticed is wear on my brushes that will require replacement within the first year. I was shocked to discover KTM does not offer replacement brushes for any of the e-starters. Does anyone have a part number from one of the other manufacturers that will interchange or a solution. KTMs' solution is to replace the starter. Cha Ching Cha Ching. So getting back to the maintenance .... keep up with it. I suspect the wear to my brushes is from dust and sand finding it's way into the starter.

panton	Posted: Sep 25 2008, 09:19 AM
KTMTalk Member Posts: 11 toronto, ON Member No.: 30368 Joined: 31-December 04	I've seen reference to "brushes" in another thread, but not sure that they are. Are they part of the stator?

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covacica	Posted: Aug 13 2008, 02:12 PM
KTMTalk Member Posts: 44 Bucharest, RO Member No.: 87329 Joined: 6-February 08	in 80h on a 08 300 exc-e, two e-starter motors went bad second one was greased every 10h a new one costs 312 euro finaly, removed motor, battery, bendix, changed the ignition cover with the one from a 250, and lost 3kgs in the process, thats about 7 ponds excuse my english -------------------- Moz --------------------- 08 KTM 300 EXC-E

FredT	Posted: Aug 13 2008, 06:31 PM
Track King Posts: 1708 Big Sand Whoops, MI Member No.: 1736 Joined: 2-September 02	2008 250 W-124 hours and it's still doing great-greased it about 4 times so far. -------------------- 2009 250 XC-We 2005 KLX 110 tricked out Member of the Lansing Motorcycle Club, AMA, D 14, D 15 and Board member of D14 Family Enduro Series. Past rides: 2008 250 XC-We 2007 250 XCW 2005 250 EXC 2004 250 EXC 2003 250 EXC 2001 KDX 220 1981 KDX 175 1980 KDX 175 1979 IT 175 1978 IT 175 1977 KD 125 1976 KD 125 1975 KD 125 1973 F6 125 1969 Honda trail 50.

vman	Posted: Aug 13 2008, 07:35 PM
Bench Racer Posts: 226 Springfield, OR Member No.: 37226 Joined: 18-May 05	I got well over 1000 miles on mine and have never even taken the little plastic protector off, let alone grease it. I figure I don't do that with my truck so why do it to a bike if you aren't having any problems. And yes, I ride in plenty of mud. The battery seems to be a weaker link than the starter. Not to mention, you don't hear anything about 4 strokers maintaining their starters, it's just because it's new on the 2 smokers. I'd figure an electric starter would have a much bigger chore cranking over a lean jetted 530 than any sized quick starting two stroke. My II pennies. vman -------------------- 08 300xcw(e) 03 200mxc

jeb

Posted: Aug 14 2008, 06:41 AM

Charter Member Posts: 43155 Rogers, AR Member No.: 33 Joined: 11-January 02

Vman, The battery turns over the 250's fine, but many have gotten the next size bigger one (5 series) for the 300's as they just need a bit more oomph. And the reason the 4 strokes don't need the amount of maint is that the starter parts get oiled by the motor oil. They run in a dry environment in the 2 strokes, so need some lube. Check out the Bulletins link in my sig and pull down the PDF file for KTM recommendations on servicing. I pulled my starter all the way down yesterday. I was bored, what can I say? I even removed the stator and pickup from the cover so I could clean everything real well and check the "1/2 tooth" measurement (mine was fine, about 1/4 tooth slop). Everything looked good, but I did note some wear on the gear teeth on the output shaft of the starter motor. -------------------- John B jejb@att.net Jeb's KTM picture pages Jeb's KTM bulletin, how-to's and misc page Razorback Riders Club Website Golden Eagles Club Website Life Member Blue Ribbon Coalition Life Member AMA 08 250XCWE, 07 200XC, 04 250EXC 2t (06 frame), 06 300XC-W (sold 4/07), 03 450EXC (sold 9/05), 01 400EXC (gone), 99 250EXC (gone), 99 200EXC, 98 125EXC (Darling wife's), 98 380MXC (long gone)

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5 4 1 2 6 3

 300XC-We starter grenades, CATASTROPHIC FAILURE

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dirty666	Posted: May 1 2008, 04:15 PM
KTMTalk Member Posts: 79 FV, BC Member No.: 82464 Joined: 28-October 07	Nasty...that's what left of my starter/nonclementure after it grenaded during my 4th ride. I bought the bike in December but never rode the bike till mid March. The starter had never worked too well, and was basically unreliable. Towards the end of the 4th ride it was totally inop. I didn't even hear anything when it packed. When I got home this is what I saw. Total destruction. Nasty. I had serviced the starter after every ride, as has been suggested on this topic. The ignition cover is cracked/blown apart. It seems like the bendix froze, and the spring seems very wimpy. The ring gear, bendix, & bevel gear are all hardened and seem ok. The starter spline is softer, and it is very worn. I called KTM Customer Service & was told to take it to a dealer and try for a Goodwill warranty claim. I really don't want to have my bike sitting in a shop for 3 or 4 weeks while this all gets straightened out, and then have them possibly deny the claim after I've waited some more. I asked KTM Customer Service for the recommended lubrication and was told to go with Lubriplate white lithium for the gears and Motorex Joker 440 for the bendix. When I enquired with a dealer this was his response email... Hello. KTM just returned my call about the starter grease. Unfortunately they were not very specific. They only recommended a white lithium grease for the gears and a spray oil for the bendix. This is the lithium grease from Motorex: 36070007 Motorex High Pressure Grease 3000 $23.95 I use these spray oils from Motorex: 36200001 Motorex Oil Spray 500ml $10.95 37040022 Motorex Joker 440 $9.95 They did say that this was a high-maintenance item and should be serviced after every ride. The didn't recommend a particular brand of oils but said they had good luck with garage door opener grease. This post has been edited by dirty666 on May 1 2008, 04:30 PM -------------------- dirty666 08 300XCWe

Steveo_supremo	Posted: May 1 2008, 04:24 PM
Berm Banger Posts: 1047 Terrace, BC Member No.: 38909 Joined: 23-June 05	If I were You I'd just remove the E-start all together. -------------------- "And We Rock....because it's Us against them, We've found the wrong reasons to sing. And it's so much less confusing when lines are drawn like that." 2006 Frankenbike Started out as a 300XC-W '06 250SX motor with 6oz flywheel weight Pro Circuit Platinum 2 pipe and Nature Friendly silencer '07 250XC dual map CDI with GasGas map select switch '07 250XC forks - Trailtrick stack '05 EXC Gas Tank (no more 1/4 turn leaker) '03 EXC subframe, airbox, side panels, rear fender and seat '08 front fender Scotts damper SUB mounted on E-rider 18mm 3x clamps BPD radiator guards Lots and lots of other Goodies

dirty666	Posted: May 1 2008, 04:28 PM
KTMTalk Member Posts: 79 FV, BC Member No.: 82464 Joined: 28-October 07	QUOTE (Steveo_supremo @ May 1 2008, 04:24 PM) If I were You I'd just remove the E-start all together. ...I'm all for that, it's useless anyways. The only problem with that is my sidecover is split wide open and I need another. -------------------- dirty666 08 300XCWe

jeb	Posted: May 1 2008, 04:34 PM
Charter Member Posts: 43155 Rogers, AR Member No.: 33 Joined: 11-January 02	Bummer. Sounds like you got one of the ones with a bad bendix. Let us know how it turns out. Mine has been great since last Sept. And I do not service every ride. More like every month or more. -------------------- John B jejb@att.net Jeb's KTM picture pages Jeb's KTM bulletin, how-to's and misc page Razorback Riders Club Website Golden Eagles Club Website Life Member Blue Ribbon Coalition Life Member AMA 08 250XCWE, 07 200XC, 04 250EXC 2t (06 frame), 06 300XC-W (sold 4/07), 03 450EXC (sold 9/05), 01 400EXC (gone), 99 250EXC (gone), 99 200EXC, 98 125EXC (Darling wife's), 98 380MXC (long gone)

DAVIDM	Posted: May 1 2008, 07:58 PM
Pit Rider Posts: 271 Waukesha, WI Member No.: 9311 Joined: 7-August 03	Guess I'll check mine tomorrow. I have 18 hours on my 2008 300 and never looked at it. Bike starts instantly. Great bike. david -------------------- davidm 2008 KTM 530 XCF-W 2008 KTM 300 XC-W(e) 2007 KTM 450 SX-F 2004 Honda 250- CR 2006 KTM 300 XC-W Gone 2006 KTM 450 XC-W Gone 2005 KTM 400 XC-W Gone 2005 KTM 525 EXC Gone 2005 KTM 300 EXC Gone Many Many More

chadman	Posted: May 1 2008, 08:06 PM
Pit Rider Posts: 396 O Fallon, MO Member No.: 36090 Joined: 26-April 05	I have never looked at my starter either. Never heard of a bike with E-start that they recommend you service that much. I will have to keep an eye on mine. -------------------- Chad 2008 XCW(e)-300 (Mine) 2008 XCW(e)-250 (Wife's) 2005 CRF-250X (Sold) 2005 EXC-525 (Sold) 2005 TTR-125LE (Sold) Life Member Blue Ribbon Coalition

dousant	Posted: May 1 2008, 08:09 PM
KTMTalk Member Posts: 29 Landmark, MB Member No.: 64239 Joined: 8-November 06	Only a few rides on my 300 and I love the button already. Servicing it every ride? If KTM actually designed it that way then that's pathetic. I guess I'll be packing a grenade as I don't have time for that much service. -------------------- 08 300 XCW 05 300 MXC

toyota_mdt_tech	Posted: May 1 2008, 08:39 PM
Berm Banger Posts: 1157 Puget Sound Area, WA Member No.: 29625 Joined: 12-December 04	It sounds liek your overrunning clutch has stuck. This will drive the starter motor at super high speeds. Usually, the overspeed will explode the armature windings from the centrifigual force. It probably finally locked up and thats when the engine cases went away. -------------------- Rick GeePaw Racing! Thanks to our Sponsors: Munn Racing "Thanks Chip" Motorex Lubricants for keeping the operation well oiled/lubed! ScottUSA for giving us a clear vision and a grip on things! Regina Chains for giving us the drive to win! ASV Inventions Levers and Perches 661/sixsixone Rider Gear Twin Air For that breath of fresh air! -------------------------------- 2007 KTM 85SX 14/17 2006 KTM 300XC-W 2005 KTM 65SX 2004 Kawasaki KLX 110 2003 Honda XR50 2002 Yamaha TTR125L 2002 Suzuki Eiger 400 4WD 2002 Kawasaki KLR650 -------------------------------- Blue Ribbon Coalition LIFE MEMBER! NMA Member AMA Member #924471 WOHVA member NRA Life Member

velosapiens	Posted: May 2 2008, 08:47 AM
KTMtalk Guru Posts: 5234 Kuna, ID Member No.: 759 Joined: 21-May 02	QUOTE (dirty666 @ May 1 2008, 02:15 PM) They did say that this was a high-maintenance item and should be serviced after every ride. That's just crazy. Why on earth would I put something on my bike that added weight and cost and needed to be serviced after every ride? I wouldn't even want to service it every month or so, but i'd rather ride than work on bikes, and kicking doesn't bother me even late in the day in a 120 mile enduro. -------------------- -this is not a signature-

FinMoto	Posted: May 2 2008, 11:38 AM
Bench Racer Posts: 192 Finland, Finland Member No.: 67801 Joined: 15-January 07	now here I go again,.... 140 hours and never opened it yet, never greased it.... Ofcourse I admit not one should break, we have here too many breakdowns vs. x delivered ? Definitely something for KTM User Service to get a grip at. -------------------- KTM 300 EXC E 2008 Ex 300 EXC E 2007 sold Ex Husaberg F650E Motard sold FLSTC 1989 in Sturgis 1996 and 1997 FLSTC 1992 in Sturgis 1997 (my wifes)

jeb	Posted: May 2 2008, 12:00 PM
Charter Member Posts: 43155 Rogers, AR Member No.: 33 Joined: 11-January 02	I don't know if I have to service mine as often as I do since so many, like FinMoto, have never even seen the starter gears. But it's easy to do and, like all preventive maint, it just never hurts to be ahead of the curve. But telling customers it needs to be done every ride is ridiculous. I'd pull it off or never use it if that was even close to the case. -------------------- John B jejb@att.net Jeb's KTM picture pages Jeb's KTM bulletin, how-to's and misc page Razorback Riders Club Website Golden Eagles Club Website Life Member Blue Ribbon Coalition Life Member AMA 08 250XCWE, 07 200XC, 04 250EXC 2t (06 frame), 06 300XC-W (sold 4/07), 03 450EXC (sold 9/05), 01 400EXC (gone), 99 250EXC (gone), 99 200EXC, 98 125EXC (Darling wife's), 98 380MXC (long gone)

scot_douglas	Posted: May 2 2008, 12:11 PM
Bench Racer Posts: 149 Canton, MI Member No.: 54032 Joined: 27-April 06	QUOTE (jeb @ May 2 2008, 02:00 PM) But telling customers it needs to be done every ride is ridiculous. I'd pull it off or never use it if that was even close to the case. That would steer me clear for sure. :/ -------------------- 2006 Honda CRF250X 2004 KTM 300EXC 2003 Honda CRF175 2002 Kawi KX100 1998 Honda XR280 Michigan CCC Member QUOTE (jeb) It's not what I'd call weird. As you can tell from the length of this thread, trying to nail down the jetting on a 300, especially for lower altitudes, is like nailing jello to a tree.

ringdingrider	Posted: May 2 2008, 12:59 PM
Throttle Jockey Posts: 586 Tacoma, WA Member No.: 83057 Joined: 9-November 07	It doesn't need to be done every ride. I did mine once. Got all of that factory toothpaste out of there and lightly lubed it with waterproof BelRay and have no problems since. I love the button. Bummer that happened though. -------------------- Ride Safe! 2008 250XCWe 2005 CRF50 (sons) 2001 CR250R (woods) spare 1973 XR-75 2002 GSXR-1000 2005 R-6 (track bike) 1988 YSR50 many others down the road

quicker	Posted: May 2 2008, 01:51 PM
Pit Rider Posts: 282 vancouver, BC Member No.: 50882 Joined: 2-March 06	Well that sucks Dirty. I hope KTM makes things right for you. I took mine apart @ 5 hours and lubed it up. I only use it when the bike is warm and it seems to work well. Get that thing fixed so we can go for a ride -------------------- 2008 XCW 300 2007 EXC 450 gone 2001 EXC 250 gone 1994 EXC 300 gone

rmcclurg	Posted: May 2 2008, 02:42 PM
KTMTalk Member Posts: 26 Chandler, AZ Member No.: 35218 Joined: 10-April 05	Thanks for sharing that info. I pick up my new 300xcwe today, I'll definitely ask them about this. -------------------- 08 300 XCWe 05 CRF450X -gone 01 DRZ400e -gone CR250R various years BlueRibbon Coalition member

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 Starter Died!, Second Time in Less Than 20 Hours

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chadman	Posted: Aug 16 2008, 06:01 PM
Pit Rider Posts: 396 O Fallon, MO Member No.: 36090 Joined: 26-April 05	Well my wife's starter died about 2 months ago and the dealer worked with KTM and paid to fix it. We just got back from Colorado with less than 20 hours on the new starter and it's dead again. I could hear a screech sound coming from the starter and sometimes when the bike started I could hear a rattle sound coming from the ignition case. It sounds like the starter was staying engaged as the bike was running. It happened to be the last day of our Colorado trip, but still a big disappointment. I had to hear grief the entire trip from our 2 Yamaha riders about the jetting issues with our bikes, over heating, and then having a starter die. I will give the dealer a call on Monday and see what they can do. I am just bummed out that this has happened twice now and the new starter has less than 20 hours on it. KTM really needs to fix this. -------------------- Chad 2008 XCW(e)-300 (Mine) 2008 XCW(e)-250 (Wife's) 2005 CRF-250X (Sold) 2005 EXC-525 (Sold) 2005 TTR-125LE (Sold) Life Member Blue Ribbon Coalition

Hokie	Posted: Aug 16 2008, 06:20 PM
KTMtalk Guru Posts: 6364 Hippie Central, TX Member No.: 8408 Joined: 29-June 03	bummer! too bad KTM jacked with the XC lineup this year and gave them this POS starter too. Glad I got a 08. -------------------- Come check out H.O.T. (Hokie's OT) http://www.sidewinder.cc/OT

Ridgeracer	Posted: Aug 16 2008, 06:35 PM
Pit Rider Posts: 309 Houston, TX Member No.: 45766 Joined: 21-November 05	Easy fix is to remove the e-start and put on the XC cover. You don't need that thing anyway. More parts = more things to go wrong. -------------------- -------------------- 2008 KTM 300 XCW-e Munn Racing - The best KTM dealer on the planet!!! Member: AMA, Trail Riders of Houston, BlueRibbon Coalition My MySpace Page

chadman	Posted: Aug 16 2008, 06:41 PM
Pit Rider Posts: 396 O Fallon, MO Member No.: 36090 Joined: 26-April 05	QUOTE (Ridgeracer @ Aug 16 2008, 06:35 PM) Easy fix is to remove the e-start and put on the XC cover.  You don't need that thing anyway.  More parts = more things to go wrong. Tell that to my wife She has a hard time kicking the bike so I have to kick it for her. I would have never gotten her a 2 stoke electric start if I knew it was going to be a POS. She loves the bike, but really has to have a working estart. Heck, I love the estart myself This post has been edited by chadman on Aug 16 2008, 06:49 PM -------------------- Chad 2008 XCW(e)-300 (Mine) 2008 XCW(e)-250 (Wife's) 2005 CRF-250X (Sold) 2005 EXC-525 (Sold) 2005 TTR-125LE (Sold) Life Member Blue Ribbon Coalition

KTMKP	Posted: Aug 16 2008, 06:45 PM
KTMTalk Member Posts: 94 Scottsdale, AZ Member No.: 41240 Joined: 19-August 05	I dont know any one that has not had a problem with the starter on this bikes,sad they are not cheap made in China bikes. Whats up KTM???

KTMMARK	Posted: Aug 16 2008, 06:45 PM
Team Manager Posts: 3266 CLARKSVILLE, TN Member No.: 5210 Joined: 25-February 03	QUOTE (chadman @ Aug 17 2008, 01:41 AM) QUOTE (Ridgeracer @ Aug 16 2008, 06:35 PM) Easy fix is to remove the e-start and put on the XC cover.  You don't need that thing anyway.  More parts = more things to go wrong. Tell that to my wife She has a hard time kicking the bike so I have to kick it for her. I would have never gotten her a 2 stoke electric start if I knew it was going to be a POS. She loves the bike, but really has to have a working estart. Heck, I love the estart myself :coo: Have you had any trouble with the starter on your bike? -------------------- 07 250 sx converted to off road. 2nd 07 250 sx project bike making it street legal (I hope) 06 250 XC-W sold 2003 200 exc sold 2001 SX 250 1997 SX 250 sold sadly

gpilot	Posted: Aug 16 2008, 06:45 PM
KTMTalk Member Posts: 15 Las Vegas, Member No.: 89388 Joined: 15-March 08	I had pracically the exact same thing happen on my 300, had a local starter repair shop rebuild my starter, as far as the noise I took everything apart twice, ordered a new bendix just to make sure, still had the noise that you are describing. When I installed the new bendix I noticed that when I installed th ignition cover that the bendix had a lot of play, it was not seating in the cover properly, took everything back apart and noticed the where the bendix is supposed to mate with the ignition cover, the indent was all worn out. It almost looks as if there should be a bushing or washer there to hold the bendix in place. I have a new ignition cover ordered(they are backordered until mid-september) hopefully this will fix my problem. As it is right now when I start the bike I get the same noise that you describe until I give it some throttle. I think that the bendix is not dis-engaging properly due to the slop that it has.

chadman	Posted: Aug 16 2008, 06:55 PM
Pit Rider Posts: 396 O Fallon, MO Member No.: 36090 Joined: 26-April 05	QUOTE (KTMMARK @ Aug 16 2008, 06:45 PM) Have you had any trouble with the starter on your bike? My bike has about double the hours that she has and is still working. I have cleaned/greased it twice now and will do it again shortly. I still cringe every time I go to start it. I have never heard of a bike that you have to worry so much about the starter. The noise her bike is making sounds bad once it is running and it only happens about every other start. It just sounds like a rattling coming from the ignition cover starter. I did not want to take it apart until I can have the dealer look at it. Since they just did the work ($667.00) less than 20 hours ago I think they should be the first to look at it. -------------------- Chad 2008 XCW(e)-300 (Mine) 2008 XCW(e)-250 (Wife's) 2005 CRF-250X (Sold) 2005 EXC-525 (Sold) 2005 TTR-125LE (Sold) Life Member Blue Ribbon Coalition

Oldman440	Posted: Aug 16 2008, 07:22 PM
KTMTalk Member Posts: 50 Mpls, MN Member No.: 9024 Joined: 28-July 03	i MUST HAVE GOTTE LUCKY WITH MY DAUGHTERS 250 xc/wE. E-start works GREAT, but I did wash old grease out immediately and replaced with hi-pressure red grease on all gears and shafts. I also highly recommend a ground wire - battery to starter motor bolt. I also run a fan on her radiator. Oldman440 -------------------- OldMan440 2008 KTM250XC/We - Beka 2005 Yamaha TTR230 - For Sale w/Ice Studs 2004 KTM 200 EXC - Adam 2004 Yamaha TTR250 - For Rent 2003 Yamaha TTR250 - sold 2001 Yamaha TTR125L -sold 2000 Yamaha TTR125 - sold 1995 KTM 440 E/XC - now Son's FUN Bike 1989 KTM 250 E/XC - sold 1980 CanAm 400 Qualifier - trashed 1978 Yamaha YZ400E - sold 1977 Yamaha IT250 - sold 1976 Yamaha TT500 - sold 1975 Yamaha MX400 - sold 1972 Yamaha RT360 - sold 1969 Yamaha 350 Scrambler + go-cart-motor

KTMwannabe	Posted: Aug 16 2008, 09:03 PM
Bench Racer Posts: 213 Quincy, IL Member No.: 16184 Joined: 15-February 04	Chad, I've been following the starter issues since I got my '08 300 XCW. I messed up my bendix spring while cleaning the the grease out of it, put in a new spring and it's been flawless. I read your KTM service buletin you found and took mine apart again to check the clearance on the gears as stated in the article. Mine had a very tight set to the gears so no shimming was needed. I'm curious to know what the clearance on your wife's bike might be. Most people with starter problems talk about hearing a screech as they hit the button, that would make sence if you have too much clearance on the gears. They would be spinning on top of each other. The thrust of the gear teeth could force the gears apart to allow them to slip. I wonder? It would be interesting to have everyone check their gear clearance when they do maintenance on the starter and post if they have excessive clearance and if they have had problems. It would be interesting to see if the tight set gears have had any problems. If KTM suggests that you check the gear clearance and they have a shim available to fix it, sounds to me like they know what the real issue is. My 2 cents. I hope you post the information your dealer finds. Pete -------------------- '08 300 XCW '05 Honda 450X - Gone '03 Honda CR250R '03 Harley Softail Radical Custom (mine) '04 Road King Custom (hers) '03 Suzuki DRZ 250 (hers)

jeb	Posted: Aug 17 2008, 06:05 AM
Charter Member Posts: 43155 Rogers, AR Member No.: 33 Joined: 11-January 02	Sorry to hear about that, Chad. None of the guys I know has had any big failures with their e-start 2 strokes, yet. Some screeching and a fairly high maint item, but still going. I did check my gear slop per the KTM bulletin the other day and I have about 1/4 tooth slop. I ordered some shims anyway just to have, but I apparently don't need one yet. -------------------- John B jejb@att.net Jeb's KTM picture pages Jeb's KTM bulletin, how-to's and misc page Razorback Riders Club Website Golden Eagles Club Website Life Member Blue Ribbon Coalition Life Member AMA 08 250XCWE, 07 200XC, 04 250EXC 2t (06 frame), 06 300XC-W (sold 4/07), 03 450EXC (sold 9/05), 01 400EXC (gone), 99 250EXC (gone), 99 200EXC, 98 125EXC (Darling wife's), 98 380MXC (long gone)

DAVIDM	Posted: Aug 17 2008, 06:12 PM
Pit Rider Posts: 271 Waukesha, WI Member No.: 9311 Joined: 7-August 03	What bulletin ? So far, no problem with mine. I never took it apart. Works great ! david -------------------- davidm 2008 KTM 530 XCF-W 2008 KTM 300 XC-W(e) 2007 KTM 450 SX-F 2004 Honda 250- CR 2006 KTM 300 XC-W Gone 2006 KTM 450 XC-W Gone 2005 KTM 400 XC-W Gone 2005 KTM 525 EXC Gone 2005 KTM 300 EXC Gone Many Many More

jeb	Posted: Aug 17 2008, 06:56 PM
Charter Member Posts: 43155 Rogers, AR Member No.: 33 Joined: 11-January 02	See the Bulletin link at the bottom of all my posts -------------------- John B jejb@att.net Jeb's KTM picture pages Jeb's KTM bulletin, how-to's and misc page Razorback Riders Club Website Golden Eagles Club Website Life Member Blue Ribbon Coalition Life Member AMA 08 250XCWE, 07 200XC, 04 250EXC 2t (06 frame), 06 300XC-W (sold 4/07), 03 450EXC (sold 9/05), 01 400EXC (gone), 99 250EXC (gone), 99 200EXC, 98 125EXC (Darling wife's), 98 380MXC (long gone)

7391tse	Posted: Aug 17 2008, 09:37 PM
KTMTalk Member Posts: 26 amelia, Member No.: 86497 Joined: 21-January 08	Grease and clean the bendix and make the bendix movese free and make sure sure your battery is charged.

chadman

Posted: Sep 7 2008, 01:29 PM

Pit Rider Posts: 396 O Fallon, MO Member No.: 36090 Joined: 26-April 05

Good news! I just got my wife's bike back today and KTM has covered the entire cost again. This last failure happened with less than 20 hours since the last starter failure. The total cost of parts and labor this time was $940.00. Last time the total cost was $667.00 and the bike had just over 100 miles on it. Anyway I am glad KTM has paid for the entire cost both times. I am still upset that it has had this much work done to such a simple part and the bike has about 600-700 miles on it. I spoke with the mechanic and he told me they had to shim the drive gear even when new parts were put into the bike this time. I just got some of those shims from Munn the other day so I can check my bike. If you have starter issues, I would talk to your dealer and see if they will fix it. It looks like KTM has been paying for parts/labor when they are taken to the dealer. -------------------- Chad 2008 XCW(e)-300 (Mine) 2008 XCW(e)-250 (Wife's) 2005 CRF-250X (Sold) 2005 EXC-525 (Sold) 2005 TTR-125LE (Sold) Life Member Blue Ribbon Coalition