ADVrider

Go Back   ADVrider > Bikes > Thumpers
User Name
Password
Register Inmates Photos Site Rules Search Today's Posts Mark Forums Read

Reply
 
Thread Tools Search this Thread Display Modes
Old 05-13-2011, 01:27 AM   #1
wherearewe? OP
Adventurer
 
Joined: Oct 2008
Location: Tanzania
Oddometer: 21
Question KTM 640 starter motor not engaging

gday all. just after some tech advice from some of you experts out there before i pull this thing apart blind.
when i try the starter, ican hear it whizzing away, but nothing happens. sounds like some gears are not engaging. i am planning on opening her up tomorrow to investigate but was just wondering has anyone had this problem before?
i have taken the cover off and the (reducing)? gear has a tooth chipped but is still spinning fine when the starter is on. guess i need to dig deeper?
the kicker works fine but im way too damn lazy to use that 24/7!
ive got an old xr for that malarky
any ideas??
cheers and beers..
wherearewe? is offline   Reply With Quote
Old 05-13-2011, 06:26 AM   #2
wrk2surf
on the gas or brakes
 
wrk2surf's Avatar
 
Joined: Dec 2007
Location: THE exact center of California/Bass lake/Yosemite
Oddometer: 6,280
starter clutch spring...
__________________
Thanks for the 2015 support: BELL HELMETS, SCOTT USA, Kriega USA, SEATCONCEPTS.COM , Carbon-pro.com, GPR stabilzers, Sidi/Motonation, Masters paint and body, Magura , Motolab , Loctite and Dunlop tires .
wrk2surf is offline   Reply With Quote
Old 05-13-2011, 08:56 AM   #3
crazybrit
Beastly Adventurer
 
crazybrit's Avatar
 
Joined: Mar 2006
Location: Portland, OR
Oddometer: 8,539
Quote:
Originally Posted by wrk2surf View Post
starter clutch spring...

to elaborate. Check out the LC4 index, search for loisu’s LC4 640 starter clutch fix. Good luck!
crazybrit is offline   Reply With Quote
Old 05-14-2011, 12:19 AM   #4
wherearewe? OP
Adventurer
 
Joined: Oct 2008
Location: Tanzania
Oddometer: 21
cheers guys. as i dont have access to springs here in tz, can i order just the spring from KTM or do i have to buy the whole starter clutch?
wherearewe? is offline   Reply With Quote
Old 05-14-2011, 09:52 AM   #5
G Goat
Gnarly Adventurer
 
G Goat's Avatar
 
Joined: Apr 2009
Location: Calgary
Oddometer: 351
SKF Seal # 19993 or equivalent. around 10 bucks from any bearing store. Make sure the cams don't fall all over the place when you remove the loose spring.
If it is equivalent, make sure of same size.
__________________
02 Ducati ST4S
08 KTM 530 EXC
03 KTM 525 EXC
G Goat is offline   Reply With Quote
Old 05-17-2011, 05:49 AM   #6
wherearewe? OP
Adventurer
 
Joined: Oct 2008
Location: Tanzania
Oddometer: 21
cheers G Goat!
wherearewe? is offline   Reply With Quote
Old 10-12-2014, 07:26 PM   #7
enzo906
Adventurer
 
Joined: Apr 2009
Oddometer: 13
starter sometimes does nothing

so what is it when sometimes it works fine and others it does nothing at all? it acts like a flat battery one time and woirks perfect another
clutch and bearing inside flywheel is OK and not locking in place
voltage is good when it does nothing
seems to hapen more cold than hot
any ideas

(bike shope said that is what the Kicker is for?)
enzo906 is offline   Reply With Quote
Old 10-12-2014, 07:54 PM   #8
clintnz
Trans-Global Chook Chaser
 
clintnz's Avatar
 
Joined: May 2004
Location: Rotoiti, New Zealand
Oddometer: 3,343
Starter motor brushes could be worn. It's very easy to remove & disassemble the starter to check. Any auto electrician should be able to fit some new brushes for you, or check out the LC4 index for where to find parts to do it yourself.

Cheers
Clint
__________________
'03 KTM 640 LC4 Enduro

The wilderness, the desert - why are they not crowded
.................................................. .....with pilgrims?
clintnz is offline   Reply With Quote
Old 10-13-2014, 07:09 PM   #9
enzo906
Adventurer
 
Joined: Apr 2009
Oddometer: 13
Thankyou for that prompt reply

Now if I can find an old leco or I guess I should do it myself :)

Why the KTM dealer did not suggest it or offer to rob me to do it is another question
enzo906 is offline   Reply With Quote
Old 10-20-2014, 02:54 PM   #10
Alik
viertaKTMotor *****
 
Joined: Nov 2010
Location: Poznan, Poland
Oddometer: 230
Quote:
Originally Posted by enzo906 View Post
Thankyou for that prompt reply

Now if I can find an old leco or I guess I should do it myself :)

Why the KTM dealer did not suggest it or offer to rob me to do it is another question
Dealers are part swapers today. They seldom repair things. You have to find a real mechanic. It is hard. Or prepare to be one if You have a KTM :)

Back to meritum.... This link maybe helpful:

http://www.xmas1.at/xneu/KATALOG/200...ter-Kohlen.pdf

The site is in German but if You want maybe write them in English and they can certainly help. A complete repair kit for the starter is available for 54 EUR + shipping.

Alternative to repair/swapping starter could be to throw out the electric leg system and return to roots - aka kickstarter. Reinstall heavier, custom made flywheel for this:

http://www.altmann.haan.de/ktm_lc4_flywheel/

Cheers!
Alik is offline   Reply With Quote
Old 10-20-2014, 10:28 PM   #11
enzo906
Adventurer
 
Joined: Apr 2009
Oddometer: 13
what about those alternative new starter motors for 131 US?
if the kit is 50 why not get the whole starter
enzo906 is offline   Reply With Quote
Old 10-20-2014, 11:27 PM   #12
Alik
viertaKTMotor *****
 
Joined: Nov 2010
Location: Poznan, Poland
Oddometer: 230
I prefer to repair things. ;) it makes me and this world better.
Alik is offline   Reply With Quote
Old 10-21-2014, 10:30 PM   #13
enzo906
Adventurer
 
Joined: Apr 2009
Oddometer: 13
Alik...
I agree but I love spares, so I get a new starter and repair the old and have a backup should the need arise
I already have alist of backups for the old girl another can't hurt
enzo906 is offline   Reply With Quote
Reply

Share

Thread Tools Search this Thread
Search this Thread:

.
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump


Times are GMT -7.   It's 08:13 AM.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Copyright ADVrider 2011-2014