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Old 12-22-2009, 11:14 PM   #136
Bonebag
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Joined: Jan 2006
Location: Wisconsin..Hot,Cold and everything in Between
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Quote:
Originally Posted by Seikkailu_R
It just make funny sound....

Its probably good idea remove intermediate gear also.

I do it few year ago when starter clutch broke middle of trip.

And after that i ride few months without that gear and starter clutch.
Good practise for kickstarting...
It's a 20 minute fix..as long as you got the flywheel puller..and part :)
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Old 12-22-2009, 11:23 PM   #137
Seikkailu_R
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Location: Piikkiö, Finland
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Quote:
Originally Posted by Bonebag
It's a 20 minute fix..as long as you got the flywheel puller..and part :)
Yes, with parts and puller...
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Old 12-23-2009, 01:04 AM   #138
warewolf
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Bit longer for me, have to replace the intermediate gear and the hub that's bolted & glued to the flywheel.

I've got a couple of years' practice at kickin' the beast, so that's no issue for me . Not riding is more of a problem!!
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KTM LC4 640 Question? Check here first --> KTM LC4 (640) Index Thread
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Old 12-23-2009, 02:02 PM   #139
warewolf
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Quote:
Originally Posted by Seikkailu_R
It just make funny sound....

Its probably good idea remove intermediate gear also.
What would make the sound?

My thinking is that with the intermediate gear in place, it will be more like 'normal' but nothing should rub or cause other issues?
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KTM LC4 640 Question? Check here first --> KTM LC4 (640) Index Thread
Quote:
Originally Posted by Steve McQueen
All racers I know aren't in it for the money. They race because it's something inside of them... They're not courting death. They're courting being alive.
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Old 12-23-2009, 02:20 PM   #140
Seikkailu_R
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Quote:
Originally Posted by warewolf
What would make the sound?

My thinking is that with the intermediate gear in place, it will be more like 'normal' but nothing should rub or cause other issues?
I dint run it with intermediate gear on place, so its starter spinning free thats make that funny sound.
At least few first times when you try start bike...

Remowing that gear is fast and easy.
And after that its same if big gear behaind flywheel spins with flywheel.
No damage to starter.
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Old 04-01-2010, 05:28 PM   #141
mstenkil
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You are going the wrong way!

Well here is a new...I think.

After several attempts to diagnose a e-starter issue, it turns out that the starter is spinning the wrong way. Go figure. Apparently brushes will wear down enough to still spin but depending on the polarity and location they can actually combine to spin in reverse.

Add that one to the list:)
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Old 06-09-2010, 07:02 PM   #142
fastwoodsracer
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Thanks for that Info! Very easy fix! Sounds sooooooooooo much better!
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Old 08-11-2010, 03:17 AM   #143
Tseta
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Well, it was only a matter of time before my starter clutch "gave up the ghost" as well. In my case, the symptoms were that the starter just spun without engaging/rotating the crank at all.

This guide has been a great help so far in performing the repair. I did not want to use the crankshaft locking bolt (in fear of damaging the crank web), so I improvised a holder tool out of a pin wrench. The pins (6mm in diameter) fit nicely in the small holes in back of the magneto (where to official KTM tool would fit as well...) to hold it in place while wrenching the nut off. One must also remember that the nut in this case has a reverse thread.



Actually removing the magneto was easy with the right puller. (Well, actually the loud popping sound that the magneto made when releasing its grip on the crank's taper freaked me out at first...) M33x1.5P (rh) is the correct size. The KTM puller kit includes some kind of protecting sleeve for the end of the crankshaft. The generic, no-brand puller that I bought did not have any protecting sleeve, but worked fine regardless.

What set me back most is the fact that the worn out sprague clutch had already roughed up and gouged the corresponding surface of the 79T-free wheel gear. (This was mentioned earlier in this thread as well?) I tried to smooth these gouges out with some fine wet-dry sandpaper. However, I now fear that to make the surface completely smooth again, I will end up taking too much material off for the starter clutch to work. On the other hand, if I leave the surface as it is now, the roughness will cause quick wear on the new sprague clutch.

A new 79T-free wheel gear will set me back more than 100 euros. I wonder if replacing the said gear is the only way to guarantee any longevity for the new sprague clutch?

I will post pictures of the worn out surface later.

Cheers,

Tseta
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Old 08-11-2010, 07:26 AM   #144
gunnerbuck
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A 1/2 copper tubing cap fit nicely over the end of the shaft to protect the threads from puller damage.... A lot cheaper than the oem $25 part...
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Old 08-12-2010, 02:49 AM   #145
Tseta
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As promised, here are some pictures of the rough, worn and gouged surface of the 79T free wheel gear.





In these pictures I've already sanded the surface down a little with fine wet&dry sandpaper. Does it look too bad?

Cheers,

Tseta
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Old 08-13-2010, 11:12 AM   #146
Tseta
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Well, I've ordered a new 79T free wheel gear. However, I will soon be leaving on a longer trip to Russia and that part will not arrive in time. Therefore, I have now assembled the bike back together with a new sprague clutch and the old gear. I guess only time will tell how long this shady fix lasts. The few tries I dared to do with the starter showed that the new sprague clutch works fine: the starter spins and engages the crank, turning the engine over and effectively starting the bike. To give the sprague clutch and free wheel gear the best chances for survival, I've decided to always try to start the bike with the kick starter. If my leg gets tired or I need to make a fast getaway (), I think I will use the manual decompressor to allow for the starter to get the engine spinning with some momentum and then release the deco to get the engine to fire up.

Thoughts?

Cheers,

Tseta
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Old 08-13-2010, 07:05 PM   #147
dentvet
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it doesn't look that bad to me and if it works, don't worry so much about it. that said, it will obviously last longer if you kick start the bike and save the button for when you truly need it. nothing wrong with kicking it over like was done on all these bikes prior to 1997. more manly that way, too
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Old 08-29-2010, 11:46 AM   #148
steve28761
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640 Starter Clutch

I tried your fix and replaced the starter brushes and it still makes a god owful noise when I try to start it any suggestions?
Thanks Steve
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Old 09-23-2010, 12:41 PM   #149
IamTRooPeR
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I am experiencing some starter clutch problems as well,

last day , tried to start with the E-start, nothing,
then the kick-start with decompreser lever, I had more trouble than normal to turn over the kick starter.
E-start didn't do anything anymore.
After some backfiring and excersising my legs, I finally got my little beast on the going.

Went home, and after trying again on the E-start. I just heard some sissing sounds. Like the starter is going around but doesn't pick up the gear-wheel.

hope the flywheel isn't too damaged nor the gear-wheel.

I don't have the time to repair myself, hope to see at the local shop what seems to be the problem. And hope more that the bill will allow me to buy any more beers......
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Old 09-29-2010, 07:58 AM   #150
IamTRooPeR
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my bike shop saw some real shit:

the srews holding the starter clutch to the flywheel made a real mess inside.

Rotor is totally wrecked
flywheel is lost

I don't get it why the srews didn't hold it.
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