2017 KTM 300EXC Electric Starter Repair
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- Опубликовано: 23 фев 2019
- XRC bronze bushing kits: www.tokyooffroad.com/product-...
This video shows the repair of the electric starter system on a 2017 KTM 300EXC with 145H. The starter operation became bad about 4 rides before the video was made and got progressively worse. On inspection the ignition case was found to be badly damaged and also the bendix bushings were found to be very worn. Replaced parts include the ignition cover, gasket, bendix and bushings (replaced with XRC bronze bushings).
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I had the same problem on my KTM on the engine side as opposed to an easily replaced cover, and I used a JB weld like high temperature epoxy resin to fill the oval wear of the bushing seat by using an undamaged bushing as a mold. I used a thin coating of a silicone grease at the back of the bushing to prevent the bushing to stick to the epoxy. Replacing the flimsy original bushings with brass ones is an excellent idea too.
My last comment wasn’t jumping on the “bandwagon “. I noticed after I made the comment that lots of people had already made similar comments. Proves your videos are truly brilliant. Just thought I’d throw that out there.
At 2:10 you mentioned putting the wrong bolts in the wrong place will lock the starter motor…that saved me a huge headache!
Same goes for the clutch cover at about the 4 and 5 o’clock positions. If you get those mixed up, which I did, the starter will not turn over. I was about the take the motor out to get to the starter. Thank you for the vid!
Very pleased to hear the video helped you out...
This and the previous video, together, they are arguably the best video resource that is available on this matter. There is more useful detail in this video regarding this nook of the starter system than there is in the official service manual for the bikes.
The advice on use of oil vs grease is a gem. My Freeride’s Bendix was all slathered in the Molykote bearing grease the factory uses. It would seem that just light oiling is necessary here. 🙏
And thank you for mentioning the Freeride specifically , it’s a bike that too often gets ignored in DIY videos. 🙏
I Absolutely love your maintenance videos. When you change your oil seals on the 2019 ktm 250 please make a video on that.
Thanks. Do you mean fork oil seals, crankcase seals, or something else?
@@TokyoOffroad fork oil seals 🤘
I made an XPLOR fork oil seal change video a while ago. Please check it out. The 2019 model is the method: ruclips.net/video/KdWAN_Vi2ZA/видео.html
I love your repair videos. Excellent job narrating. Your repair videos are always interesting and informative. I don’t even own a ktm and I watch every vid. Wish I could afford the bikes you two have. Keep these vids coming.
EXCELLENT video. Just bought the bushes from your site along with some other tools. Great work on these videos man, please keep it up! When you drop them I watch them right away- I ride a lot and do all my own maintenance and your videos have been invaluable. I'm kinda hoping your clutch side main seal goes so I can watch a video of the repair, as mine is probably the culprit of gear oil in my exhaust!
Best how to vids on RUclips. I don’t even have this bike but enjoy watching 🙌🏻
I replaced mine today my bike only has 35 hrs on it and the Stock bushings were fine but I believe I just save myself a headache down the road thank you for the product and the information in this video
Hello, just wanted to thank you for your professional videos very good delivery. I just purchased the bronze bushings and oil drain tool from your website keep up the amazing vids!!
Thank you so much for this video. And thanks for mentioning the bolts on the clutch cover at the very beginning. Saved me a lot of time pulling off my starter cover.
This is just what I needed to see - my starter just failed - 2019 KTM 300 - THANK YOU!
I just did this on my 2018 Husqvarna TX300. The bike has 50 hours on it and the stock bushings were still fine. Both the ignition cover and case bushings were the shallow bushings. You may see on Tokyo Offroad's website that he suggests you check your bike to see if either bushing is deeper than the other. Mine were identical so I bought the XRC 2017 250/300 kit. Both stock bushings came out with relative ease using a pair of squeeze-to-open pliers and a twisting motion. Both XRC bronze bushings were still a tight fit that required hammering into place as shown in this video on the ignition cover bushing. So, I did not use Loctite. I also lubed the gears with a lighter engine oil 5w30 rather than grease to be sure the bendix did not get gummed up.
Your video is very thorough and well put together. Keep them coming
The best repair video I have seen. Thank you great job.
Love you Videos, honestly the best place to come for real detailed and honest repairs and info for these bikes! Thanks for taking the time. Any chance you have tried the GET'S new 2T ECU and Injector Kits. Supposed to improve bottom end??? Not cheap tho especially here in Australia like everything else. Thank again.
Hello! I just got the xrc! Thanks for everything! Greetings from Madrid
Oskitar makinote - Great. Hope the installation goes smoothly
super vid ...my starter motor holder holes were loose so I retapped them to a bigger size and with the snug tight fit it finally works ..
I had done more or less everything else including new bendix and was just about to give up .
I bought your XRC bushing kit for my 2015 TE300 . From Tokyo Offroad (you) a few weeks back. WOW, I really believe there's less friction now, starter has more torque to deliver to the flywheel . I'm hoping the Starter Bushing might last a bit longer. I use Lucas X-Tra Heavy Duty Grease. I add Tungsten Disulfide (WS2) and mix, works super well. Super slippery, is inert, non-toxic, and non-corrosive. Thank you.
Ray - I’m pleased to hear that the XRC bronze bushings are working well in your bike and appreciate your business. I’d recommend a period inspection and re-lubrication if required and they should last the life of the bike.
that puller is INSANE! cool, but insane! I just used a flat head screwdriver that was about the same size, they turn prety easy in the housing so they just come straight out
Really enjoy your videos so informative! Q. Is this the same for KTM 4 Stroke engines?
Thank you.
Absolutely brilliant
Have just bought a 19 300xc and looking around for common issues so I can keep an eye on them.
Just looked up part numbers for these bushes and compared from 17-19 and looks like a different part number now, weather this is a good thing or not I don’t know but sounds promising lol 👍🏻
How is the fit of the new bronze bushing onto the bendix? You showed the old worn out one but I am curious how the fit of the new aftermarket parts are. Very nice video.
On such an expensive bike why are there no roller bearings for the bendix is it because of weight savings? Also I read that some people will fill the case up to the bendix with a light weight oil to keep the components lubed and last longer the only downside i can see is if the starter seal might allow oil into the starter motor, thoughts?
On my EXC 300 MJ17 (EU) there is only one bush (in the cover). On the engine housing the bendix sit´s in without bush and works will since 130h.
Thanks for the video. Symptoms of worn bushes? My 2017 300 starter is just makes a clicking sound on the relay. I checked voltage on the battery and it 12.7V. I first suspected wiring or bad earth.
R Parks have you removed the clutch cover recently? If so, you probably put the bolts in the wrong order and the starter is binding. If not, check voltage at the starter motor. Make sure you are getting 12v.
Great info. Thanks
Great vid, Where do you get the bushing puller and slide hammer?
It’s an import blind bearing puller set (made in Taiwan?). I purchased it at a local tool shop in Japan about 5years ago.
Hi mate, Do you know how to remove the starter motor on a 250 exc 2018? Can’t find any videos online for that year.
Any recommendations of what compound to use if you have more slop? I feel mine has even more movement than yours, perhaps a different locktite?
noahr - Check out this document. Near the bottom is a table with recommend maximum gap. Loctite 648 is recommended for gaps up to 0.15mm, 638 for gaps up to 0.25mm and Loctite 680 can be used for gaps up to 0.5mm with activator: dm.henkel-dam.com/is/content/henkel/RetainingDesignGuidepdf
Can you put a small amount ,say 50ml, of oil in the cover to lubricate it ? A friend of mine has done it and seems ok .
Great video as usual ! Any idea if these fit a 2018 150xc w
The 150 bendix bush part number is the same as the 250/300 so should fit fine.
Can you do the wet mod / breather mod like on the earlier bikes? IME, this made the system longer lasting. I know that slavens raved then slated this mod for some reason.
Good vid, great repair. 🖒🖒
What type of oil did you end up using for the bendix? I was thinking a high quality gun oil would work, I have a ton of Mpro 7 on hand. Going to do the bushing install sometime soon, not an emergency, should I just order the motorex 2000 instead?
Yes, I think that oil should work well. A light weight oil which doesn't go tacky is fine...
Quick note on the clutch side bolts (this lead to me having to replace the starter motor) Not sure when it changed, but on my 18 300 xcw manufactured around September of 18, the stock clutch cover comes with a bigger space on that one bolt which prevents you from accidentally driving it too far and all of the bolts are the longest version vs. one being a little shorter. Great update, however if you have an aftermarket cover, in my case the hinson, even if you are careful and put the bolts back in the same place, now that that bolt is also longer it will go through the starter motor.
good job bro thanks
Do you think this may apply to the four stroke motors too and does XRD make bushes for them?
Very informative video
The four stroke electric starter systems (starter motor engages directly with a gear system) are quite different from the 2-strokes. The bushes and parts used are also different. The XRC bronze bushes are for 2-stroke applications only.
@@TokyoOffroad thanks for the quick response and info much appreciated
Very useful videos ! Can you please make a video with starter. How is removed ? For 2017 model.
Munte fly - Noted. Will do...
@@TokyoOffroad thanks !
I think Phill needs to buy a new bike ! I think you have replaced everything on it with him by now ! But these are great videos, really informative thank you. Also bought your oil drain attachment and it is fantastic, makes oil change super easy.
Well that's ktm for ya 💁♂️💁♂️
What type of oil are you using? I read somewhere fork oil would work.
Great video! 1 thing, i don’t understand why there is a slit in the bronze bush? As its a dry case? No oil.
Thanks
As mentioned in the video I used some light weight oil (which doesn't tack up) on the flywheel and bendix. Excess oil will be flung off, some of which may drip down on to the bushing flat and then seep into the bushing to lubricate the bendix shaft.
I have a 2020 Ktm Xc-w with 18 hours the starter spins over but doesn’t engage, I carried back to my dealer and the replaced the starter drive and it started one time and did the same thing. They are taking apart again tomorrow , have you seen this on a 2020? Thanks
I sounds like it’s probably an issue with the bendix.
i cant seem to find these stocked in Australia do you ship if so how much? cheers
Thanks for your interest. I'm happy to ship Worldwide. Normally I ship to Australia using Japan Post Registered Airmail which costs US$7 to post an XRC bushing kit. However, currently due to Coronavirus the service to Australia is suspended. I can ship using Yamato (with final delivery by UPS) but the minimum cost is US$25 for up to 2kg shipping weight.
Great video! Any chance you can provide insight on removing the bendix? I’ve got bike apart and can’t get the bendix past the fly wheel. I bought the bronze bushes, any help is appreciated!
Mike Rasmussen - There is just enough room to remove the bendix with the flywheel and starter motor installed. As such all you need to do is remove the ignition cover and you can the take out the bendix. It’s very easy if the engine case bush is worn. If however the bush is new you’ll need to jiggle the bendix about a little, but it can be done. The same is true for installing the bendix.
The bike is newer. 3 rides on it. And it’s a 2018 so it should all be the same. I’ve got the cover off, bike laying on the side. I pull the bendix straight up and the base below the engagement sprocket hits the fly wheel. It appears you have more room around the fly wheel. Mine is a XCW 6days. Not sure if that makes a difference. Thanks for the reply.
Mike Rasmussen - The bendix will come out without removing anything else. Try moving the flywheel to and fro while juggling the bendix. It’s tight and a bit like a puzzle, but can be done without damaging anything. The same is true for re-installing the bendix following bushing replacement.
Tokyo Offroad I gave it another go tonight and you’re correct it will come out. I cleaned everything and coated the fly wheel, bendix, starter gear with the Motorex Spray 2000 which made everything more slippery. Once I got the bendix pulled up to where it hits the fly wheel, I gave it a bit more “muscle” with my hand (no pliers or tools) and with the extra effort yank, it came out. I think lubing everything very well aided in the removal. I really appreciate the extra help on this. Had to do 3 bikes, my KTM and my sons Husqvarna 300’s. Projects completed. Great high quality products you’re selling. Can’t say thanks enough.
Mike Rasmussen - That’s great. Pleased to hear it was successful.
Great video!! Just a heads up, Phil's cylinder base gasket is flipped the wrong way. It should not be sticking out that far under the left power valve cover. I made the same mistake on my 17' 300xc.
Oh dear. His 300 kit was installed by his dealer :-O it’s due for a top end overhaul soon so I’ll be sure to install the new gasket the right way round...
Ugh oh I might have done the same. In sure it won't affect anything will it?
Why do you have to pull the flywheel off? I've watched several videos and it seems like the flywheel has to come off to get the bendix out, but you can get the bendix out without taking the flywheel out. Is it just for ease? This would be for the entire starter motor repair.
No, you don't need to remove the flywheel. The bendix will come out without removing the flywheel, as shown in all of my videos for XRC bronze bushing installs. But if you do remove the flywheel it is without doubt easier to remove and reinstall the bendix.
How about a video on eliminating the starter?
Hello.
How long the xrc bronze bushing last?
The XRC bronze bushes should last the lifetime of the bike with periodic inspection and lubrication. As I mentioned in the video, it is important that when installing them they are held in place and don’t spin in the bore. Because the OEM bushes can easily deform and wear the bushing bore you may find when installing XRC bushings they have some play and can be rotated. If this is the case some retention compound (E.g. Loctite 638, or 648) can be used. If however the bore is badly damaged, or cracked it should be repaired, or replaced before installing XRC bushings.
is this also for a 2018 300 xcw?
Yes
where do those bushings ship from. I want to order some. But if they're coming from overseas, it's useless right now because of the covid-19 crisis
Thanks for your interest. I ship from Tokyo, Japan. So far shipping times don't seem to have changed that much to most countries. 7-10 days to the US.
I just checked some recent shipments. Some seem to be arriving on time, others are delayed. I spoke to the Post Office and the number of flights has been reduced so they said delays are occuring. If you need a bushing kit quickly I can ship by EMS (which doesn't appear to be delayed, 5 days to US). You can contact me here: www.tokyooffroad.com/contact/
Do you need shims with these at all?
No, shims are not used
I have 3 bikes. A 2018 KTM 300 XCW and (2) 2018 Husqvarna TE300. I ordered 2 of the 2016 packs as I need 3 bronze bush sets, and will have an extra set as a back up. These will fit my 2018, correct? Great video and thanks so much for putting this all together!
Thanks for your order. Yes, they will fit your bikes no problem. The only difference between the 2 kits is the number of bushings (2, or 4).
Thank you, Sir!
Mike Rasmussen hello Mike I just replaced the bendix and oem bushings I also installed a new lithium ion battery. I can easily kick start the bike (Ktm 2016 xcw) one kick but when I use the e starter I can hear the piston Turning and bike attempts to start but it just wont turn over any ideas? I was thinking maybe replace starter but it seems to be fine
Other than that the bike runs great any help appreciated
We3K1ngs make sure your battery is pushing over 14 volts to engage the starter. My bikes are 2018 so my starter system is different then yours. I’m not familiar with your system. Sorry.
We3K1ngs Hey We3K1ngs did you ever figure your issue out? I am having a VERY similar issue with my 2016 Husky te300 (mostly the same bike as yours).
I wonder why on those new bushings that the flat had to be facing / pointing up?
The flat is designed to collect oil and then drip it on to bendix shaft to help ensure good lubrication
@@TokyoOffroad Hello thanks for your reply but I wasn't aware there was any oil in this area of the engine?
@@outbackenduro7418 - Normally there isn’t. From the factory grease is used to lubricate the flywheel teeth, but it flings off very quickly and can make it’s way inside the bendix, making it sticky. For this reason I recommend using some light oil (select one which won’t tack up) to lubricate the flywheel and bendix gear teeth as shown in the video. Yes it will fling off, but drip down again unlike grease. Oiling should be repeated periodically during the starter system inspection.
Ktm just can’t seem to get a solid starter motor setup on the smokers for some reason
Agreed. Definitely an improvement over older bikes, but the decision to continue to use of the original bushings is baffling
any oil you would recommend? would the transmission oil work?
Transmission oil is a little thick. 5W fork oil would be better.
@@TokyoOffroad thank you!
The best mechanic online!!! Does xrc have a kit for beta?
Thank you. You should be able to use the XRC 2020 kit (2 long bushings) to replace the stock Beta bendix bushings: www.tokyooffroad.com/product/xrc-starter-bush-kit-250-300-2t-tpi-2020/
@@TokyoOffroad
Do you ship to Israel?
If so, what is the shipping quote?
Thank you
@@hershko85 Normally I ship to Israel using Japan Post, but currently the service is temporarly suspended due to Coronavirus. However, I can ship using UPS. If you'd like a quote please contact me here: www.tokyooffroad.com/contact/
Did you have to go to the dealer for a new bendix?
Yes, a new bendix was purchased from my local KTM dealer.
@@TokyoOffroad thx brother. Starter is acting up on my 18. I can hear the starter spinning but not engaging the flywheel. Gonna have to inspect it but I'm thinking it's the bendix.
My starter doesn't even do anything anymore. My starter relay actually caught fire as the starter wires were ripped out of the housing in behind the headlight due to a fall. The wires crossed themselves and were engaged for I don't know how long, but long enough for the relay to catch fire.
Time for a new starter motor, I guess?
Wow! One quick check you could do to see if the starter motor is still OK is apply 12V directly to the starter motor terminal and see if it turns over. If it doesn't turn over with 12V applied directly and the bendix isn't jammed, then it would indicate that you do need to replace the starter motor.
@@TokyoOffroad and the terminal is on the clutch side of the bike, correct? Below the expansion chamber where the wire connects?
@@EricNeilson_ Yes, that's correct. The terminal you can see is for the +12V connection. The ground connection is through the body of the motor and connects to the battery via the engine and frame.
It’s a 300 sorry I forgot to put that
Nice repair... But fixing the case would be cheaper.. We are not rich.
The ignition cover cost is about $80. The cover material is magnesium and would require TIG welding then machining. I have kept the old cover and may try to repair it at some stage for a spare.
Stock bushings are a joke. So is the bad designed gear to shaft bonding on the bendix.
wet mod!
Need to get Snap On tools on board with some tool sponsorship Mark. I cringe every time i see your spanners :-) sorry i am a snob lol
All my sockets and spanners are KTC (Kyoto Tool Company) and made in Japan. Excellent quality, reasonable price and available broadly in Japan. I've never broken a single KTC tool in all the years I've used them. Highly recommended. They have a bling bling line too to compete with Snap On called Nepros but I prefer not to need to wear sunglasses while working on the bike ;-)
You can see the basic tools I use in this video: ruclips.net/video/mLUxMKEMeug/видео.html