To remove the primary gear nut, instead of using a quarter in the gears to keep from moving (as suggested in the video), I slid my clutch basket back on to interlock with the gear, used my clutch basket holder tool to keep it all from spinning, and then simply used an impact on the nut. After a few tries, the Loctite loosened-up and the nut came free. Just remember it is left hand thread so use the impact in the forward position. This is a great video, thanks for posting it.
I did the spring replacement using a cheap rear main seal as a donor on my 640 and it worked just fine for thousands of kms. It was pretty worn with irregular pattern but still grabbed properly. Literally a $10 fix.
Great video. I think I have this same issue. I only wish you had posted a clip off the "before" attempts at starting so we could confirm our own issue sounds the same. also, you state you can leave the water pump cover on, and while technically true, one of the cover bolts also holds on the clutch cover and needs to come out to remove the cover. And thank you for the parts list!
Thanks for the video. I have a '14 450xc-w looks like all the part #s cross reference except main gasket. My symptom is just the starer whining 4-5-6 seconds and not turning over the motor. Once warmed up it will whine less and then catch and turn over. Not the starter, and not the battery so guess it's time to pull it apart and see if this is the culprit. Much appreciated on the walkthrough. Here is the list, there is one replacement part # and the gasket part # is off by 1 digit for my bike. pricing from RMATVMC and AOMC for the puller. Part Part # Parts schematic Starter/Freewheel gear 78940020033 $72.19 Electric Starter - #21 Primary Gear 78132000032 $60.13 Crankshaft, Piston - #14 Freewheel Clutch(Starter Clutch) 76640026000 $65.43 Electric Starter -#23 replaces 75040026000 (old part#) Clutch Cover Gasket 78130027000 $6.92 Clutch Cover - #3 Outside Cover Gasket '14 450-xcw 78130105000 $16.32 Clutch Cover - #4 (This is not the part # for my bike: 78130125000) Special Tools Puller 75029021000 $68.00 Protective Cap 7502909000 $20.00 est Total $308.99 Have been using the kick starter a lot lately! KEK
Thank you so much. My 15' fc450 snowbike having same issue. I don't think I'll try the $10 spring fix and opt for full replacement. Starting is critical out in the snow!
The Mark on the primary gear does this need to lined up with my clutch basket teeth at some certain position. My manual says to have the piston at top dead center while performing this work. I know my manual breaks down the hole rebuild on the motor step by step but I am not rebuilding the hole thing so does top dead center matter while just replacing the parts in the video? And the blancer on my water pump shaft does that need to be reinstalled or lined up at some certain position while installing the cover? These starting issue have been the down fall of my bike and am stoked to find this video. Thanks bud!!
Hey Man, KICK ASS VIDEO! This fixed my 2015 Husquvarna FC 450 dirt / snow bike (i ride the yeti 129). I also chased down the torque limiter as the issue, but that was not it. Your video was spot on, followed it (with the exception of the KTM tool) i used a gear puller that you can borrow for free from the autoparts store with a ratchet strap around the bottom to keep it from slipping of the main gear (saves the $120 1 time use part). We ride Kootney pass alot in the winter, hope to see you out there! Thank you for the excellent video!
Hey I have a 2004 KTM 450 SMR and I bought the starter for it cuz this one came without the starter and I'm kind of lost as how to put it in and I also have bought the Haynes service and repair manual is there any way that you could help me out and like kind of walk me through it
Great video Duggy B was it absolutely necesary to replace the primary gear or starter gear ? i have same issues with my ktm 520 exc. Sprag seal was loose as yours. Thanks
great video! how were you able to rule out an issue with the torque limiter? i have read some forums and found guys saying they simply had to tighten the bolt holding the limiter on.
I have a 450 SXF it’s a 2016 special edition. It’s acting like the battery is not throwing the starter Period the starter and gauges it does not engage the motor. I bought a new battery I just put it back together and about every other time To start it will catch the motor and start to turn it over but quickly just engages and just spins. And I’m talking about the starter spinning. Also appears to take the battery down pretty quickly when it does that Period is this a common trait to diagnose if it’s the clutch for the starter.?
Sir good day, do u have specific size or measurement of the free wheel bearing? The inner and outer diameter as well as the height. I have 2009 ktm sxf.
If this piled up when the bike was running would it cause the engine to bind? My 2014.5 450 sxf wont start, but the starter motor when removed from the bike still runs fine. Could this issue bind all those gears so the starter cant turn them?
Replaced the spring on freewheel to address starting issue but weird thing. Kickstarter is now engaging gears (in nuetral). What the heck could that be. Put everything back together correctly....several times. Starter appears to be fine.
Thanks for this suggestion. I haven't pulled a gear before so just checking a regular bearing puller works the same way and would not damage anything else on the bike? Assume it cost less than the $70 the tool cost from KTM?
@@MrDrisok not sure where you and the video creator are getting this $70-100 figure for that golden puller. its a $30 part on AOMC. "KTM Primary Extractor Tool 75029021000"
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I've got this problem! Ktm starter whirs up good, but doesn't turn the engine. Thanks for the run through.
To remove the primary gear nut, instead of using a quarter in the gears to keep from moving (as suggested in the video), I slid my clutch basket back on to interlock with the gear, used my clutch basket holder tool to keep it all from spinning, and then simply used an impact on the nut. After a few tries, the Loctite loosened-up and the nut came free. Just remember it is left hand thread so use the impact in the forward position. This is a great video, thanks for posting it.
I did the spring replacement using a cheap rear main seal as a donor on my 640 and it worked just fine for thousands of kms. It was pretty worn with irregular pattern but still grabbed properly. Literally a $10 fix.
Thank You my 2013 450sx-fe is having this problem,life saver,these things work great until they don't !
Great video. I think I have this same issue. I only wish you had posted a clip off the "before" attempts at starting so we could confirm our own issue sounds the same. also, you state you can leave the water pump cover on, and while technically true, one of the cover bolts also holds on the clutch cover and needs to come out to remove the cover. And thank you for the parts list!
Man was searching for weeks to figure out what was wrong with my ‘13 450sxf, stumbled across this vid and this is he exact problem
same here, this seems to be the starter fix for my 2008 Husky. I hope I wont need to order the gears cause these might be expensive :(
Thank you, it saved my day on my 2013 KTM 450 SXF. Thank you for adding the parts list as well.
No problem 👍
I had this problem wish I had seen this video then. 100 thumbs up
Wow!
Thank you for making this video!!!
Exact problem I’m having on my 2014.
Thanks for the video. I have a '14 450xc-w looks like all the part #s cross reference except main gasket. My symptom is just the starer whining 4-5-6 seconds and not turning over the motor. Once warmed up it will whine less and then catch and turn over. Not the starter, and not the battery so guess it's time to pull it apart and see if this is the culprit. Much appreciated on the walkthrough. Here is the list, there is one replacement part # and the gasket part # is off by 1 digit for my bike. pricing from RMATVMC and AOMC for the puller.
Part Part # Parts schematic
Starter/Freewheel gear 78940020033 $72.19 Electric Starter - #21
Primary Gear 78132000032 $60.13 Crankshaft, Piston - #14
Freewheel Clutch(Starter Clutch) 76640026000 $65.43 Electric Starter -#23
replaces 75040026000 (old part#)
Clutch Cover Gasket 78130027000 $6.92 Clutch Cover - #3
Outside Cover Gasket '14 450-xcw 78130105000 $16.32 Clutch Cover - #4
(This is not the part # for my bike: 78130125000)
Special Tools Puller 75029021000 $68.00
Protective Cap 7502909000 $20.00 est
Total $308.99
Have been using the kick starter a lot lately! KEK
hi great video just wondered how you put the sprag back on while holding the half noon keyway in place thanks
Thank you so much. My 15' fc450 snowbike having same issue. I don't think I'll try the $10 spring fix and opt for full replacement. Starting is critical out in the snow!
Exactly the video I needed, thank you good sir ! Have a nice one
This video is very helpful! Thank you!
The Mark on the primary gear does this need to lined up with my clutch basket teeth at some certain position. My manual says to have the piston at top dead center while performing this work. I know my manual breaks down the hole rebuild on the motor step by step but I am not rebuilding the hole thing so does top dead center matter while just replacing the parts in the video? And the blancer on my water pump shaft does that need to be reinstalled or lined up at some certain position while installing the cover? These starting issue have been the down fall of my bike and am stoked to find this video. Thanks bud!!
Thank you man for the content my 2018 started doing this and this helps
Hey Man, KICK ASS VIDEO! This fixed my 2015 Husquvarna FC 450 dirt / snow bike (i ride the yeti 129). I also chased down the torque limiter as the issue, but that was not it. Your video was spot on, followed it (with the exception of the KTM tool) i used a gear puller that you can borrow for free from the autoparts store with a ratchet strap around the bottom to keep it from slipping of the main gear (saves the $120 1 time use part). We ride Kootney pass alot in the winter, hope to see you out there! Thank you for the excellent video!
Glad it worked for you I ride down there lots!
When iddeling can sound like a bad crank? or creates problem only on start?
Hey I have a 2004 KTM 450 SMR and I bought the starter for it cuz this one came without the starter and I'm kind of lost as how to put it in and I also have bought the Haynes service and repair manual is there any way that you could help me out and like kind of walk me through it
Great video Duggy B
was it absolutely necesary to replace the primary gear or starter gear ? i have same issues with my ktm 520 exc. Sprag seal was loose as yours.
Thanks
Thanks a lot buddy. will do this weekend !!
G'day man, just a question if you don't mind?, That tool you brought is the inner thread 50mm or 1.95 inches? Awesome video aswell thanks
great video! how were you able to rule out an issue with the torque limiter? i have read some forums and found guys saying they simply had to tighten the bolt holding the limiter on.
Because I saw the clutch pack was in pieces, when I reinstalled I torqued it so even if that was an issue k would have solved it there most likely.
I have a 450 SXF it’s a 2016 special edition. It’s acting like the battery is not throwing the starter Period the starter and gauges it does not engage the motor. I bought a new battery I just put it back together and about every other time To start it will catch the motor and start to turn it over but quickly just engages and just spins. And I’m talking about the starter spinning. Also appears to take the battery down pretty quickly when it does that Period is this a common trait to diagnose if it’s the clutch for the starter.?
Sounds like the issue yes
What way does the arrow face on the sprag bearing when reinstalling cheers?
Ii do not remeber this was a number of years ago sorry
Sir good day, do u have specific size or measurement of the free wheel bearing? The inner and outer diameter as well as the height. I have 2009 ktm sxf.
I don't
Again this is me adding a starter to the bike and I've also got the factory battery and factory battery box to go in also in the wiring
Great video Duggyb
Saved my day
Im having the same issue with my 2019 250 sxf where the starter just spins freely but it doesnt crank will this also fix that?
it could be.
If this piled up when the bike was running would it cause the engine to bind? My 2014.5 450 sxf wont start, but the starter motor when removed from the bike still runs fine. Could this issue bind all those gears so the starter cant turn them?
Duggyb B no turns out i blew a valve. Wasnt too bad since i could still turn the engine over but still blew out the whole top end
Is this fix good for 15 300 xc 2stroke all so with the same issue
i dont think so no.
Replaced the spring on freewheel to address starting issue but weird thing. Kickstarter is now engaging gears (in nuetral). What the heck could that be. Put everything back together correctly....several times. Starter appears to be fine.
Hy, same problem on 450 2012?
for the primary wheel you can also use a regular beraing puller. No need for a special tool :)
Thanks for this suggestion. I haven't pulled a gear before so just checking a regular bearing puller works the same way and would not damage anything else on the bike? Assume it cost less than the $70 the tool cost from KTM?
@@MrDrisok yep, its cheaper and works just fine.
@@MrDrisok not sure where you and the video creator are getting this $70-100 figure for that golden puller. its a $30 part on AOMC. "KTM Primary Extractor Tool
75029021000"
I pulled it out without any puller...
My starter is slipping on my 15 husky fc450 probably the same problem, not looking forward to fixing lol
its not too bad!
@@kyushalimit5931finally getting around to it but the puller is backordered till mid July
@@TheBuuurnz I will sell you my puller and cap if you like? Email me duggyb@gmail.com
Of course KTM has a special fuckinh tool
But thanks for the great help
great video. thank you
Orientation of the freewheel ?
How do I remove the clutch bracket
Price of this puller in Germany ist 24 USD, sellers are crazy...
Where Plz? Do you have a Website address to buy that at this price? Thanks.
@@victorSarramalho AOMC has them for $30... first site that popped up when I googled the part number in the video wtf