KTM starter problem slow crank solution and bendix fix
HTML-код
- Опубликовано: 8 окт 2015
- After several hours and several hundred dollars my KTM starts like a champ
KTM XC XCW electric starter motor slow crank speed fix problem upgrade bendix solution diagnose repair 350W 410W watt
Link to Sunday Rides video • Sunday Rides - "KTM B... 
Авто/Мото
Thankyou for this video, I bought my kit from slavens and had it delivered to Melbourne in only 7 days, fitted the crown, bendix and starter. I was sure my battery was no good but all was fine, the KTM 200 2013 model now starts very easily, thanks again for the info.
Hi Dave, glad to hear you were successful. Hope to ride in your country some day!
Wow what an ordeal you went through , glad you got your bike up and running . Im glad my video helped and thanks for the shout out , greatly appreciated . If you could put the link in the video disruption it will be easier for others to access the video in the future . thanks again and ride like the wind .
+SUNDAY RIDES Hi, I added your url to the description. Is this what you meant.
yup thanks
Thank you! 2015 bendix and gear, I’ll try that next.
I had looked from france. I have the same problem one my 2015 freeride 250. Was not sure that i have problem whit my bendix until i hear your bike trying strating. Thanks !!!
Thinking about this a bit more. You notice that when I hit the starter button at one point in the video (after new bendix installed) it didn't crank and the starter motor stalled. This is because the piston was just coming up on compression and the starter didn't have a run up. With the slipping bendix gear the starter motor would turn the engine to that point and then I am guessing cannot bring it any further because it didn't have enough momentum. It seems to need a bit of speed and the assistance of the flywheel to get the engine over the compression stroke. With the slipping gear the starter simply can't get the engine spinning fast enough in the limited time it has to make it over.
Thanks for the vid! I was just about to start this whole process. I will try the bendix next instead of a new motor, battery, and wet mod. I hope it works! I have a 2011 KTM 250 XC-W.. Braaap
HI Jimmy, if you check the bendix for either problem (bent or slipping) and find an issue it does require replacement. If it passes however, you likely have another issue. Hope you can solve your problem with a minimum of $$$.Please post the results of your bendix test. Wondering how many of these are out there......An easy way to see if the battery or wiring is an issue is to use jumper cables (carefully!!) and connect directly to the starter terminal and ground at the starter case using a good battery (vehicle battery is a good source). If it still won't crank properly you have eliminated the bike's battery, wiring and relay. Much cheaper than replacing these parts and still not having it fixed. Remember to only connect for a very few seconds to the starter. If it doesn't crank you will overheat the starter very quickly and can end up with more than one bad part.I highly recommend the wet mod, Slavens Racing site has excellent detailed instructions. I am pretty sure I would not have had a rusted starter if I had done this after my first season. Sitting for a few months with water in the flywheel housing is not at all good for metal.
+Dale Wells new 2016 Bendix and crown fitted the Bike starts perfectly with the original starter motor.
That's awesome Nigel, thanks for updating. Lets both hope the parts last!
On my 300, I have added a wire to ground the starter directly attach to the frame and it realy give me some extra power, the motor is ground by the bolt that old the cover and when oxidation start, ground became bad and it start randomly. When ground goes bad, it make starter overheat and can blow it!
Great tip, thanks for sharing.
First time I've saw this video. I have a 2011 KTM-300 xc and put a 410 watt starter motor on it and also a EarthX lithium battery and my ol'20+1 runs great.
2011 runs great!
Got to say, so far (think its now at least 4 years), the lithium battery I installed still works great. Great to hear your experience is similar.
Hey great video. Im currently going through these pains on my 09 250 xc. My question is did you replace the flywheel too? you said drive gear in the video, but Im not sure if you meant the idler gear or the flywheel. I certainly hope its not the flywheel cause that is much more expensive. Thanks.
Thorgeirn Stormcaller Hi, it was the transfer gear, not the flywheel. Best of luck with repairs!
I've been chasing the same problem on my 2008 KTM 300. Voltage drop checks out, New starter motor, new crown gear. Worked like a charm at first, got hot and quit working. I'm checking the crown wheel bushing and shim setup next.
Hi Steven, did you check the bendix while apart? Also may require checking V drops while hot as sometimes a connection or the relay may work OK when cold. Good luck and please post outcome. There do seem to be different causes of the slow/no crank issue.
BTW, now nearly Sept, have done recreational riding as well as 4 Hare Scrambles and starter still working perfectly.
It opened/expanded easily, but I never thought to check to see if it spun on the shaft. When I get it apart, that will be my next check. Voltage drop while hot isn't the issue. Replaced the wiring and ran a direct ground to the battery. It all checked out ok. I'll post up with my learnings...
How is is cranking? Slow, not at all?
+Dale Wells - it sounds just like yours at the beginning of the video. After 3 or 4 attempts, it stops all together and I just hear the relay click. Relay has been replaced too. The only thing that hasn't been replaced are the crown gear bushings and the Bendix.
Definitely check the bendix.
Just a stupid question since I have the exact same issue with my husaberg: is the broken part of the bendix you showed us the torque limiter or are these two different parts? Because in a forum all I here is torque limiter haha. But great video!
Should I expect a 2013 300xc to e start fine with the upgraded bendix and crown wheel? I've got the new gear combo, bushings, gaskets, 410W motor from amazon, charged Shorai 240CCA Lithium battery, everything greased and it barely makes it past the compression stroke when the bike is cold, but at room temp. Kickstarts fine and after warmed up, the starter cranks over quickly. Tried jumping it with a car battery and also a booster pack. Still no good. I'm wondering if it's just a crappy starter motor or maybe the battery is old..any suggestions for what to try next?
Hello Geir, mine will start when cold but cranks slower. Also may require hitting the button more than once if it’s near the compression stroke on the first try. Depending on how long it’s been sitting and temperature I may use e start or kick it on first start. My luck with aftermarket starters was not good, it was not nearly as robust as the KTM one.
@@2strksrule Thanks for letting me know. Good to know. I'll probably just kick it cold then use the cheapo starter when warm. Maybe upgrade to the KTM starter if the cheap one fails.
Useful info thanks
So that stutter starter was do to the bad bendix and crown wheel? I replaced my starter motor (it was definitely done) now put it in and my starter stutters just like his in the beginning. I’ve seen the bendix and crown wheel at slavers racing
Hi Nick, testing the bendix is easy. Just put the small gear that engages the flywheel in a vice or similar. Then extend the bendix and turn it until it is fully extended. At that point it should lock and you shouldn't be able to keep turning the drive gear. If you can, you will notice that the drive gear is spinning on the shaft. That is what causes the engine to not spin up fast enough to get over compression. Also check to see if the shaft is bent. If both are OK, replacing it wont help your starting problem. Also good to check clearance on the bushings while you are in there.
@@2strksrule I put the flywheel back in with cover and checked the back side to make sure it was less than 1/2 tooth clearance. Brand new 410 watt starter in it. Bendix spins freely one way but when extended locks out. It does the wind up but stalls then winds up a few seconds again later like seen in the video. I think I hear you saying that’s more indicative of a bad bendix?
Hello: I have a ktm 300 exc 2010 with problems in the electric start system. my English is not good. Did you finally solve the problem by changing the bendix and flyweel of 2015? Could you tell me the codes of the parts that I have to change? . Thank you very much
Hello Pablo, the parts required are the Bendix and the crown gear. They are both required because of the different tooth spacing created by the change in ratios. Here is the link to the kit on Slavens Racing site. You will also need a new gasket which is included in the kit. Good luck and please post the results of your repair.
slavensracing.com/shop/2015-bendix-crown-wheel-upgrade-kit-for-ktm-husaberg-husqvarna-200250300/
Thank you very much!!!
I heard it's a good idea to clean your e starter system once a year gonna try this on my 250 xcw
James Panda - Yes, if you do not do the wet mod, the starter and bushings should be serviced every year.
Hi, i have same problem on my ktm 300 xc 2011 so can you get me the part number or the link to buy de new bendix and the gear
Hi Geo, here is the link to Slavens. They ship to many places. slavensracing.com/?s=bendix&post_type=product
My 300 2013 has a similar issue wont start cold it just locks up.
sometimes when it is warm it will crank over and start
but the majority of the time it locks up.
I have checked the starter does work off the bike and also the bendix is not slipping it may be a tad bent but not alot at all.
So could it just be the starter is warn out since sometimes it starts?
This issue has got me confused and i dont want to buy a starter and a bendix since one is working properly
+Micheal Rex Hi Micheal, think I would try jumpers to the starter from a good battery. That way you can eliminate some parts. If it still doesn't crank properly at least you know it's either the starter or bendix. Of course this is assuming you don't have a mechanical issue. Suggest you also check the bushings in the cases for wear. If it kicks over smoothly it's probably safe to say the mechanicals are good. Good luck and hope you are successful.
+Dale Wells fixed the issue :) just gave it a service re greased and cleaned everything and new bushes.
It was getting jammed because the bushes were worn out and it was jamming up the gears when engaging.
happy days
+Micheal Rex All's well that ends well!!
Just a thought, did you try the old starter motor on the bike? Does it still work?
Nigel, I haven't re-installed the old starter but I'm pretty confident it will work based on how it cranked with the bad bendix. Actually keeping it as a spare....
Having same issue with mine. About to do same repair, how long did you get out of the new setup?
Rcovry Still working fine, have put it away for the winter.
Make sure u get the latest model of bendix that is lazer welded, last three digits in part# is 400, i did the upgrade the bendix last digits 300, was pressed on and failed within 6 months, another 100plus dollars and im on my 4th starter!
can this be happening on a bike with starter clutch?... not same kind of bendix...
I'm sure that is possible. If you figure out the power flow through your starter system you should be able to test the parts to make sure they are holding. Keep in mind most issues are electrical on a typical starter system.
Just ordered this kit for my 2013 300xc. EXACT same problem yours was having!
DoubleDeuce Reviews Please post up results.
Did it work
April 2018; long term review of starter repair. Tear down to see how it is holding up. ruclips.net/video/Q86vwveShtU/видео.html Bendix still holding with no slippage. Other than bushing wear, the inside of the stator cover was clean and no condensation was present. Lith Ion battery still appears to be holding up fine with strong cranking speeds and good stamina.
Any chance you have the 410w product code ?
Sorry, threw the box out. However, the P/N is easy to find. Google it or Rocky Mountain MC has a great online OE parts lookup tool.
where did you buy the other bendix here in canada?
I bought it from Slaven's Racing in the US. They are standard parts available at a KTM dealer. Just make sure they are selling you the upgraded parts (you can tell by counting the teeth, pointed out in the video).
that's just the 2015+ bendix right?
Yes, if you are switching up from a prior model year you will need the crown gear as well. If you are buying over the counter may be a good idea to open the box and check to see if the gear is laser welded to the shaft. There are some photos showing the difference online
Dale. Did this starter mod work in the long term.
Mark, I sold th ebike in July 2022, starter was still working.
That's exactly what mine is doing.
2014 ktm, aftermaket starter new, new batter 12v 6ah 130CCA still wont turn over same problem, relay jumped and still the same thing so thats not the problem. the only thing i haven't done are the bendix and crown wheel replacement but i don't know if i want to spend that much money on this system
bike is a 2014 exc 300
Take the bendix out and test it, if it fails at least you know you're spending the money wisely. Put the smalll gear in a vice (gently) then wind out the bendix till it reaches full stroke. Then take a large plier and put some torque on it. If it slips, its failed.
BTW, mine is still working, several years later. Have some friends who weren't so lucky but I think they hit the starter when rolling backwards. That will break them quickly. Now looking at TPI's. They look like they can be interesting.......
My bike has the exact same problem. I'm just waiting for parts. Will post up if it works with old starter. Thanks.
Thanks Nigel, hope it solves your problem without the expense of a new starter. Please do post your outcome.
I cannot believe I spent 9K on my 14 300,and am going through the same BS with my bike. Who knows the cost when done.
80 hours and dead starter. 13 volts to starter cable barely turns/grinds over
Hi Brad, feel your pain. However, just fired up the bike for the first time this year and starter still working perfectly. It appears that doing the mod and using the new parts is a good fix. Please post what you find and keep in mind Nigel's comment about reusing the original starter. You may be able to get a kit for your starter motor if it needs work. My bike is now going into its 5th season and has otherwise been bulletproof. Cannot say that for many of the other brands being ridden in our group so am trying to keep a balanced opinion. Gets easier with each trouble free season:)
Brad, I got the same issue with my 300, 2014 w/74hrs...new starter, batt at 13.8v new bushings but still clicks just like dales's...going to order Bendix kit like Dale, see what happens
this has to be my problem... install new starter and same thing happens. ordering a bendix as i type...
Ross Elzinga Hi Ross, have to tested it for slippage or being bent? Please post your findings.
ugh, well the bendix didnt fix it... :( - but i found the bushings are worn out, i would think it would still crank to start with worn out bushings but im not sure. ordered a new ignition cover because bushings were worn through the cover, will update when parts get here.
Worn through to the case? I would suspect that would be a problem. That would permit a huge amount of lash in the gears and everything would be out of alignment.
New ign. Cover and bushings. Cranks as it should!!!
Great to hear and thanks for posting results!
Very nice vid! I'm struggling with the e starter in my sxf at the moment ruclips.net/video/_i_8ULNksx8I/видео.html haven't yet opened the clutch side from the engine, but could my issue be related to bendix as well?
Wow, you definitely have something slipping in there. Your voltage is holding up well enough. I cant hazard a guess because I am not familiar with the 4 st starter system but think that torque testing the bendix would be a good start. You may want to continue researching to see if anyone has posted about this issue. Not sure if the ring gear is part of the flywheel or pressed on, that could also be cause of slippage. Think there may some signs of heat at the slip point as well judging by how fast the starter was turning without the engine turning at all. A careful inspection should reveal something but I'm betting it's not electrical. Please post the outcome, am curious what you will find.
I got the bigger starter on Ebay for much cheaper.
Perfect example of "my bike has a problem lets just throw money on it without doing any research"
Maybe your compression was too high
Update June 6th, 2016. Bike sat all winter, brought it out in April and starter working great. Did not take it apart as wet mod should have solved lube issue and vent sealed at bottom with hose from top running inside of frame. Lith iron battery held charge and is now in third year. Hope I'm not tempting fate with this update....:) I see KTM has completely redesigned the engine for 2017 and starter now mounted parallel to crankshaft. Looks like a better design but think this will serve for a few years more.