How To Inspect and Replace a KTM Motorcycle Starter

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When you need to service your dirt bike starter motor, you can count on Rocky Mountain ATV/MC. We carry OEM dirt bike starters - just take a look at our OEM parts page. But why not consider an aftermarket starter? Many discover that they like them just as well as the originals. Our brands of choice for dirt bike starters are Arrowhead and Nuetron, both renowned companies for their quality aftermarket products.
KTM OEM PARTS
www.rockymountainatvmc.com/oe...
Part #'s from a 2015 KTM 300 XC-W
COLLAR BUSHING
Part# 55140030100
BENDIX
Part# 55140026300
CROWN WHEEL
Part# 55140022300
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[@arijany69]

Thanks a lot for this instructional video, I followed 100% beginning to the end. My starter needed to be replaced. I ordered on internet the starter “410”, bolts kits (replace all rounded bolts) gaskets (startor and fly wheel)waterproof grease , brake cleaner, and bushings) it took me 30 minutes to dissemble and another 30 to assemble!!! Estimated mechanical labor with parts $480 I spent $145. Definitely I recommend this video. Thanks again.

[@rmatvmc]

That's great to hear, that's exactly why we do these kinds of videos! Thanks for the positive feedback!

[@driesoberholzertswanafuel9109]

AWESOME Video thank you - without knowing anything on the topic i am ow comfortable enough to go and look at my bike and see what's up with it!

[@jasonlawrence7283]

Amazing video, was doing some research for a friend and this video explained everything perfectly!!

[@jeffflick602]

Getting a updated starter for my 2011. This video was excellent!

[@DerekDuVelleDrives]

Amazingly clear video and so helpful.. I am in the progress of rebuilding my '13 Husaberg TE300 top end and thought I'd give the ignition system a going over at the same time. Thank you for this, made it very simple to understand.

[@billg1374]

I'm in the exact same boat right know. My 2013 KTM manual calls for Molykote 33 medium grease but that shit is expensive. What did you use? I see in the vid RM used Belray Waterproof which I do have.

[@DerekDuVelleDrives]

@@billg1374 I use Corrosion Block by the same company that make ACF50 on everything! Look it up I'm not sure whether it is available in your region but well worth the buy if to get it sent!

[@TomGlander]

Looks great. I just ordered the fuel filter.

[@itairam1]

Great tutorial, helped me a lot with my Freeride 250R!

[@rmatvmc]

Love to hear it!

[@andretait2817]

Now that was a nice quick and helpful video

[@Cyril_Harperink_87]

Thanks for the tips !

[@themarkcabalteam]

GREAT video! No grease required on bushings?

[@GaryLaaks1]

Great vid tks Dustin.

[@RoofRack2]

Very well made - got a lot in there. Cheers

[@jimpoteet1]

need this one for the xcfw 4 stroke starter.. thanks

[@keinanafek7388]

Thanks for the video

[@georgemelcer]

Any suggestions on where to find the starter solenoid on a KTM 690 SMR?

[@demimurgatroyd7705]

Thanks for the good quality video perfect

[@kenneychappuis1853]

Nice job. Thanks

[@MrMrsregor]

my 2003 ktm 625 sxc starts to turn the motor over but then lots of banging and clucking. it sounds like the starter is disengaging while still trying to turn the motor over. it looks like it has NO bendix when i look at the parts diagram ? all i see on parts diagram that looks like it might replace a bendix is a "free-wheel-gear" and a "free-wheel-Fwd" am i missing something or are those the parts that i might need to replace ?

[@yesno3031]

when i hold the start button nothing happens, no sounds nothing. could it be my battery? my dirtbike havent been touched in 2 years but runs great with the kick starter

[@iToddi]

What size drill bit did you use to pull the bushing?

[@markboileau3486]

Great video, I love the detail, very easy to follow!

[@rmatvmc]

Thanks *Mark Boileau!*

[@brodyhildebrandt7921]

So I bought a 2016 500 KTM exc supermoto. Bike has good tight compression, starts on 1st,2nd or 3rd kick. Electric start will make a wining sound and some clicking then turn over after a good 15 seconds or longer by holding the starter down. Is this needing a new starter ? My only thought I have and/or bendix too.

[@jayfowler9260]

I have 2004 625 lc4 the intermediate gear is obsolete can I upgrade all the gears with a new starter since I can't get the one for the bike.

[@neildickson4897]

with a good battery my 250 sxf starts great but while the bike is off it drains battery over night.can you tell me what the problem may be?

[@gregz198]

My e-start will only start the bike when the choke is on, even when the engine is hot. Does this indicate a problem or do I just need to increase the idle speed?

[@slinginleaddownrange223]

What bushing driver tool are u using in this video?

[@dhanrajbhagwandin2616]

excellent knowledge thanks for the information

[@stuartbellwithvintage2stro375]

Carb/brake cleaner

[@iTGbuDeeV]

Great video. What type of cleaner are you using, and what grease?

[@rmatvmc]

We're using Bel-Ray Waterproof Grease and PJ1 contact cleaner. You can check it all out here: www.rockymountainatvmc.com/Sales/917/How-To-Inspect-and-Replace-A-KTM-Starter

[@surg23]

Awesome vid. What is the spray stuff you are using for cleaning ?

[@rmatvmc]

www.rockymountainatvmc.com/parts/pj1-professional-contact-cleaner-p

[@Harnosharn]

I have a 2010 ktm 300 exc, my starter motor is gone , makes a dying kinda noise when I try it .. doesn't start but sounds strong every time "click click click" now I'm a useless mechanic ! Is there any easy way to just take off old starter put new on ? Would that work instead of the lengths you guys went to ?

[@jacobdobson15]

Anyone have a part number on the bushings that have the orange Teflon on them?

[@vihanthamaraka3047]

i've honda hornet 250 i got same shit like tik tok when i start the engine thank you bro i has buy a new starter motor

[@ride4funnomg103]

Where can I find the shims for the idler gear?

[@ADRENERGlC]

What is the spray used for cleaning?

[@leadinghealth3859]

Thanks for this!

[@rmatvmc]

Glad it helped!

[@franfranmotorsport5105]

Somone buy a aliexpres 410w start for the ktm? Any opinion?

[@darrylallwright6432]

I have a 2015 husky te300. Mine cranks 100 but does not start especially when cold. What can it maybe be?

[@dougnval]

I am replacing the starter, crown wheel and Bendix on this same bike next week. Parts ordered but one of the parts that I got was a Bendix spring. What is that used for? Also, when buying OEM Bendix and crown wheel the exploded image shows the bushings on either end of the part. Are those bushings included with the part when the parts are shipped out? (I didn't see a part number to order the bushings otherwise)

[@minkkinennn]

GOOD STUFF

[@ToddtheLoneDroner]

How much of a difference is this between the 950 adventure... As I will starting a bike I let go of the starter button it continued to turn over even after I turned the key off the starter would not stop ... Eventually the battery got hot and went dead.. Any idea what could cause this dude

[@keithwinsor2431]

Hey Dustin, great video i've watched it many times. I've had a starting issue with my 2012 KTM 300 XCW since i bought it used 4 years ago.Back when I bought it the starter would only start the bike after the bike was hot and not every time. I've replaced batteries, crown wheels, bendixs' and starters. If I try to start the bike cold the system does not have enough power to turn the engine over unless i take out the plug and is noisy when it does crank over. I was at a loss to what the problem was but I may have figured it out. When I purchased the bike I noticed the left rad had taken quite a blow, enough to bend the support bars that run horozontally across the rad itself. If I look straight down from over top of the cases I can see that the bolts that hold the starter motor together run at an angle in respect to the engine cases and I'm now wondering if the starter motor has taken a blow and is causing some misalignment issues. Can you tell me if I'm on the right track, I've tried just about everything else.

[@rmatvmc]

*Keith* when was your top end last serviced? If you pull the exhaust off and look up the exhaust port you should be able to see what the piston and cylinder look like. Our mechanic Steve says he would want to start there, first. Let us know what you find out!

[@keithwinsor2431]

@@rmatvmc No engine has run like a charm for years. Last week I replaced the starter motor and now the bike will turn over cranks about three revolutions then comes to a dead stop. I'm thinking it's gear lash. I bought new bendix crowm, bushings and a starter after we last spoke. Turns out the starter was crap (bought it from someone else). Getting closer to having a 2012 300 XCW with an operational starter. Will keep you updated.

[@10630079]

Gutes Video!

[@artbrunazzi2694]

Hey RMATVMC, when putting the flywheel back on is it important to have the piston set at top dead center for correct ignition timing? I know there are marks on the flywheel for where it should line up at top dead center. Thanks!

[@crazybob1954mo]

Art , No engine does not have to be at TDC. There is a key on the shaft and flywheel will only go on when the slot and key are aligned with each other.

[@stevenmcallister2230]

Hi my when I press my start button it’s trying to start but doesn’t fire up what could the problem be

[@finadhona2068]

can the starter motors be re-rolled

[@ady23nos]

But why u put in 350w starter and take off the 410w?? I knew is new one but is weaker.

[@fredman1085]

I guess I need to do this, my bike either starts, or goes clank (no start), or zzzzzzz (no start). I guess it's a project for my rainy Saturday coming up.

[@chadsley132p]

All the collar bush’s the same sizes ? Iv got 2012 Ktm 250 exc and is there 4 of them

[@rmatvmc]

Yes, the 4 collar bushings on the ignition cover and starter are the same size.

[@mikeboyer1114]

Can you link the flywheel clamp? Having trouble finding it.

[@rmatvmc]

Here you go! www.rockymountainatvmc.com/parts/tusk-flywheel-pulley-holder-p

[@SBKRIDER_1]

My KTM LC4 640 Supermoto 2003 keeps losing batery power, I take battery out and recharge it manually, few times after driving the bike and recharging the battery my bike stopped working while I was driving it, I tried to turn it on and it wouldn't. I came home and charged battery again but it didn't want to start at all. 10 days later I still can't start the bike, the voltage regulator is dead for sure, but why the bike won't start ? Also I took the battery from my second bike which I also drive and my KTM JUST WON'T START AT ALL. The mechanic guy told me that it has spark and it's not about eletric, it's mechanism type of problem. PLEASE HELP

[@raymondvandenbroek9833]

You never inspected the contact points inside the starter, i just needed to clamp the positive connection abit (the other en of the bush), it might have burnt due of overusing one day and stopped working. But thanks anyway

[@Adzy222]

Sub frame is missing a bolt btw :P

[@rmatvmc]

Thanks *Adrian Mayfield* We were tackling a couple of maintenance jobs at the same time. Good eye!

[@markparent3323]

The stator and rotor are two separate pieces. The stator (coil) is stationary, the rotor (magnet) rotates. A stator-rotor is not a part.

[@v2ikek8lm]

what grease are you using?

[@rmatvmc]

We used the Bel-Ray Water Proof Grease in this video. You can check it out here: www.rockymountainatvmc.com/parts/bel-ray-water-proof-grease-p

[@jamiewilson21]

How do i tell if my bendix is a problem?

[@rmatvmc]

If the bendix is bad, you'll hear it spin but the engine won't turn over.

[@DerekMerrill-ty2ir]

Where does wires go

[@liamstewart389]

What is he using to clean the parts?

[@rmatvmc]

That is PJ1 Professional Contact Cleaner. You can check it out here: www.rockymountainatvmc.com/parts/pj1-professional-contact-cleaner-p

[@dirtbagseth]

Can you just replace the motor without taking the rest apart?

[@rmatvmc]

If you want to replace the starter motor without inspecting other components, you can definitely do so!

[@Gimmethepuck]

My 2014 KTM 300 XC-W clicks when I hit the start button but starter does not turn over, only a click sound. When I connect starter to battery it spins great. What is my problem? Brand new lithium battery. Thx!

[@248rok]

I have the same problem. New battery, motor spins ok and i have changed the boshings, but the engine doesnt start :(

[@crazybob1954mo]

Geezz... SO, Install Four New Bushings... But Don't Bother to Put Any Grease on Them During Assembly... Not Too Smart... >;) Please Be Sure To Grease Your Bushings During Assembly..