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Old 11-23-2012, 08:12 AM   #1
mcma111 OP
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Location: San Francisco,Ca.
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KTM 625 SMC Starter Problem

Have a 06 KTM SMC with about 8K on it. Earlier in the week when starting the bike the starter would make a kind of clacking noise when used. Yesterday I tried to go for a ride and all I get now is the starter motor just spinning with no engagement to the motor. What am I looking at replacing??
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BMW's
58 R26
79 R100s
91 R100gs

87 Harley FXRS-SP ~ 06 KTM 625 SMC ~ 72 Honda CB750/915cc ~ 92 XR600/654cc ~ 95 XR650l/675cc ~ 03 CRF450r ~ 05 CRF450x ~ 02 XR650l/675cc ~ 86 YZ490 ~ 93 YZ80 ~ 93 XR650l Project
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Old 11-23-2012, 10:24 AM   #2
SlickSix
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Hey steve. Im not familiar with the starter motor on KTMs but on my F4i I had a similar problem. The motor spun freely but would not engage.

The starter clutch was slipping.
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Old 11-23-2012, 10:30 AM   #3
mcma111 OP
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I called Munn Racing in Texas and have ordered the one way bearing and the collar it spins in. Now all I need to find is the flywheel puller as I don't want to spend $60.00 for the KTM tool.
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Steve in SF

BMW's
58 R26
79 R100s
91 R100gs

87 Harley FXRS-SP ~ 06 KTM 625 SMC ~ 72 Honda CB750/915cc ~ 92 XR600/654cc ~ 95 XR650l/675cc ~ 03 CRF450r ~ 05 CRF450x ~ 02 XR650l/675cc ~ 86 YZ490 ~ 93 YZ80 ~ 93 XR650l Project
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Old 11-23-2012, 10:33 AM   #4
SlickSix
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Do you have the thread size at hand? I have a few lying in the shed, maybe one fits
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Old 11-23-2012, 11:03 AM   #5
mcma111 OP
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There is a fella at work that might have the puller. No worries. I'll buy one even if it only gets used once. NOT going to the dealer. Never, ever.
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Steve in SF

BMW's
58 R26
79 R100s
91 R100gs

87 Harley FXRS-SP ~ 06 KTM 625 SMC ~ 72 Honda CB750/915cc ~ 92 XR600/654cc ~ 95 XR650l/675cc ~ 03 CRF450r ~ 05 CRF450x ~ 02 XR650l/675cc ~ 86 YZ490 ~ 93 YZ80 ~ 93 XR650l Project
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Old 11-24-2012, 09:03 AM   #6
bmwktmbill
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Wanta borrow mine.

It's factory.

Mail from Wisconsin.
bill
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'02 KTM 640 Adventure-lowered
"On the road there are no special cases."
Cormack McCarthy-The Crossing

The faster it goes the faster it breaks.
And high performance=high maintenance.
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Old 11-24-2012, 11:34 AM   #7
mcma111 OP
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Thanks Bill. I'll find out Monday if the fella at work has one as he recently bought a LC4 bike and his started died. He bought the tool I believe.
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Steve in SF

BMW's
58 R26
79 R100s
91 R100gs

87 Harley FXRS-SP ~ 06 KTM 625 SMC ~ 72 Honda CB750/915cc ~ 92 XR600/654cc ~ 95 XR650l/675cc ~ 03 CRF450r ~ 05 CRF450x ~ 02 XR650l/675cc ~ 86 YZ490 ~ 93 YZ80 ~ 93 XR650l Project
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Old 11-24-2012, 10:15 PM   #8
bmwktmbill
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OK, BTW anyone who rides a R100GS must be....

As for the R26, had one in college, no muffler...piece of chrome vacuum cleaner pipe...1968.
Loud. Madison, Wisconsin. Police riots. U of W.
Magneto problems....
bill
__________________
'02 KTM 640 Adventure-lowered
"On the road there are no special cases."
Cormack McCarthy-The Crossing

The faster it goes the faster it breaks.
And high performance=high maintenance.
Bill Shockley

bmwktmbill screwed with this post 11-24-2012 at 10:25 PM
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Old 05-20-2013, 07:32 AM   #9
mcma111 OP
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Fixed

I forgot all about this thread. Anyhow I ordered the forward freewheel bearing and freewheel hub from Munn Racing. I searched and found a Motion Pro puller on Amazon.com so I had the correct tool for the job. My buddy at work broke his KTM tool the first time he used it so I went with Motion Pro.

After the parts had been on the bench for a month or so I finally decided to install them. On went the hub and bearing. At start up it sure didn't sound very good. My son took the bike out for a spin and I didn't start the bike for a couple of days. It sounded terrible so back apart it came. My brand new $90.00 bearing was destroyed and the new hub was chewed up. FUCK!!! Called Munn and Chip said he would give me a break on the next one. As luck would have it he charged me full boat. Nice.

Took the hub to work and the machinist polished most of the damage out. This time I greased the one way bearing and the install was done in a few minutes. The bike started up just fine with no more noises. Previously when I would stop the engine I would use the kill switch and just as the engine is coming to a stop the one way bearing would engage and make a noise so now instead of the kill switch I pull in the decom lever and the engine stops without a peep. Sucess, finally.
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Steve in SF

BMW's
58 R26
79 R100s
91 R100gs

87 Harley FXRS-SP ~ 06 KTM 625 SMC ~ 72 Honda CB750/915cc ~ 92 XR600/654cc ~ 95 XR650l/675cc ~ 03 CRF450r ~ 05 CRF450x ~ 02 XR650l/675cc ~ 86 YZ490 ~ 93 YZ80 ~ 93 XR650l Project
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