Hi, I,m currently having problems with my starter, if you goto the ktm640 thread under thumpers there is a fault finding how to, have you check relay, 20 amp fuse, wiring, my starter problem is in the sprag clutch (starter just wirrs)
I kick my 02 by doing the following
Little choke 1/4
Slowly kick bike to compression stroke ( kick starter won't move)
Pull in manual decomp, so just past compression stroke, about 1/4 movement of kick starter.
Release decomp and good kick off kickstarter and bike fires up every time.
Also if you google ktm640 electric start you will find info.
All the best