How-to Troubleshoot KTM 250/300 E-Starter

Jeff Slavens demonstrates basic diagnostic troubleshooting for the KTM/Husaberg/Husqvarna 200/250/300 e-starter system.
slavensracing.com/?s=e+starte...

[@barryspindler8342]

Thank you Jeff. Having a 2013 300 with electrical problems that was right on the money for me. Very well made video. I do appreciate your helpful videos.

[@brucehayward8728]

Thanks Jeff! Your logical and linear approach helped me find my problem.

[@jasondodd6525]

Thanks for taking your time and giving your knowledge Jeff

[@parv100]

As per your usual high standard. Fantastic video !!! Explains things so so well. Thank You. For your time and effort.

[@2ttrails521]

You are the most informative person on this topic, very good break down on everything to check. Thanks man keep up the great work

[@JoeJoeMoto]

Good stuff. I replaced my starter on my 08 300 with the 410W one and haven't looked back!

[@StephenMHicks]

Thank you Jeff, this helped me troubleshoot my issues.

[@slaverace1]

Glad to help.

[@kevkev2320]

Great video. Sorted mine. It was the starter motor for me. Thanks

[@stuartlyons8638]

Just stumbled on your video, wow a great help and very easy to understand the testing procedure for a newbie off road rider! I will definitely be doing these tests to try and sort my Huskie te300 2016 🤞👊

[@slaverace1]

Glad it was helpful!

[@stuartlyons8638]

@@slaverace1 are the eBay units any good only I have found the relay is corroded badly and the starter is rubbish (thanks to your video ofcourse) I just don’t want to spend circa £300 or $450 oem parts to fix it if the eBay ones are going to be roughly £100 $150 ?

[@patfitzgerald9000]

Very logical step through guide.

[@rossconsalvo6792]

Thank you! Great info, very well done

[@chasecarmody9876]

My bendix had a broken spring inside that I bought from ktm for $1.50. Saved me the entire cost of a new bendix. So yes, a bendix is worth repairing actually. And parts for them can be bought, although very few.

[@scarzpt]

How can i change the bendix spring from the e-starter? Have you some video? thanks

[@sean172]

hi jeff slavens I've done every thing you have said on all the videos have a good lithium battery checked the crown to see if it needed shims had a new bendix last year put new bushes in greased it all up and when i start the bike i hear a grinding noise so i took the crown wheel cover off the crown is spinning along with the bendix why would this happen would it be the bendix is not disengaging fast enough I've tried every thing and don't want to keep on throwing more money at it I've looked every where and can't find any one having this problem any ideas

[@michaelruthers6358]

Hi jeff i have a 2013 ktm 250 sxf the battery does bot seem to charge on the bike, can fully charge it and itll last 2 hours then click click click battery drained ive replaced the rectifer but still the same and videos or heads up at what could possibly not be charging the battery!!! thanks

[@DigitalZombie90]

Thanks Jeff, fixed my bike using this video. It was the relay cable.

[@chanakyasinha8046]

What if cdi is bad or termination unit? My bike doesn't getting the voltage on the control side of relay of e starter

[@juliandevr1]

Thank you very much on the tip to jump the 2 cables on the solenoid. Mine was clicken as i should. But my motor wont spin. After jumping the cables with an screwdriver the motor begin to spin.

[@briangonzales5121]

What was the problem? Mne is doing the same thing.

[@sanfeliperun]

Just picked up a 2015 350 xcf. After 20 minutes of riding, electric start stopped working. Just clicks. Going through this diagnostic instruction. Battery is at 12.5, solenoid makes clicking noise, it sparks when using screwdriver to bypass solenoid but doesn’t turn over. Follow cable down to Do the light test on starter and light only gets dim, not real bright. What does that mean? Do I need to replace the electric starter motor? Never got to any zinging, just the click.

[@warhorse0815]

hey jeff, i love your vids. They helped me few times on my 08 EXC 300. I replaced my battery for a 4A bat, bought 410A startermotor, and replaced the crownwheel und bendix for the new 2015 model. Now i only need to install the new bushings and shims from your shop and do the wetmod and it should run. What a crappy construction.

[@Jrod_FPV]

did you ever get it working ok ?

[@warhorse0815]

@@Jrod_FPV lol yes i got it in working condition. Lasted maybe one or 2 weeks. This shit is fubar. 🤷🏻‍♂️

[@Jrod_FPV]

@@warhorse0815 oh bummer. What failed the 2nd time? Did you narrow it down to electrical or mechanical failure?

[@banditkeith80]

Ive got a 2014 husqvarna tc250 that starts and then after a half hour ride or more will not start again unless i wait 15 to 30 minutes. Its like its dead and the switch does nothing. After 15 minutes to 30 it will turn over. But it wont do again for 15 to 30 mins after which it will start turning over. Any ideas?

[@mas4133]

Just viewed the video 1st time. Something else for folks to look at is the negative (ground) side of the circuit. I had replaced many components (i.e., battery, relay, rebuilt starter, etc) on my '01 400 then came to find that the ground circuit from battery to starter motor was marginal to deliver the electrical current capacity needed. Since that is accomplished by cable to subframe, then subframe to main frame bolts as well as main frame to engine, corrosion at one or many attachment points was my culprit! i simply ran another ground wire from negative battery terminal to the starter motor mounting bolt to achieve better/ redundant ground circuit.

[@deanowilliams6400]

this worked a charm for me in getting the motor to crank thanks. still no spark though arghhh

[@Jrod_FPV]

What symptoms were you having? Mine is a weak cranking motor, so weak that sometimes it will turn over, and some times it gets stuck and doesn't crank through the compression stroke. The other thing is that when it does crank/ turnover, the bike doesn't start. It's almost like there's no spark, because when i kick start it 2 seconds after a failed electric start, it starts right up. I think i have a bad connection in my circuit ?

[@Jrod_FPV]

@@deanowilliams6400 I'm having similar symptom, did you ever get yours working? What was your culprit ? Mine is a weak cranking motor, (new motor and gears) so weak that sometimes it will turn over, and some times it gets stuck and doesn't crank through the compression stroke. The other thing is that when it does crank/ turnover, the bike doesn't start. It's almost like there's no spark, because when i kick start it 2 seconds after a failed electric start, it starts right up. I think i have a bad connection in my circuit ?

[@deanowilliams6400]

@@Jrod_FPV running an extra wire from the negative terminal on the battery to the starter ground worked surprisingly good! Much better cranking power! I had other issues but the starter turned the crank no problem after that. May have got a new lithium battery too I’m not sure. No longer have the bike

[@buddieswithdirtbikes3224]

Any ideas if everything’s getting power but the solenoid doesn’t click and the starter won’t jump? I put a new starter in it thinking it went bad but still the same. .17 300xcw

[@jameshickson385]

just had a problem, you should always be checking the solenoid fuses, they can blow and it is a very easy fix

[@dmorgan3244]

I have a 13 300XC with a Slavens replacement starter it in....when the bike is cold and I am trying to start it in gear with the clutch pulled in, it won't start. Sometimes it will start in gear when the bike is warmed up. Hope this isn't a dumb question but does clutch adjustment play any part in that? I asked because even when kicking the bike over in gear, the bike wants to lurch forward (so the clutch isn't disengaging enough) but when the bike is warm it won't usually do that. Does that make sense?

[@Regan_Tatham]

I have a 200 xc-w and the clutch doesn't fully disengage meaning that it doesn't usually start in gear unless I kick start it, this is most likely because it has after market clutch plates in it that might be too thick. However another problem that you might have is running oil that is too thick meaning that the oil can't get in between the clutch plates. This would stop the clutch from fully disengaging.

[@denouden92]

Perfect! Thank you Jeff. It was all in my shitty battery and how it just doesn’t have enough juice to start it

[@Just_B_ok]

Nobody mentions if you do put a new relay in make sure the positive goes to the post that powers the solenoid. Otherwise you won't get any click or anything. I learned this when I rebuilt my bike. Had the battery going to the wrong relay post.

[@mattie_world]

got this on my 2018 tpi, i guess i’m getting a new starter motor then

[@bearbeau13]

Hey Jeff, looking at your video because I'm having an issue with my 2021 300 xc. I jumped the solenoid and it turns the starter every time. Nothing from the start button. I also have a 2021 350 that starts fine so I robbed the solenoid to see if that would work... Nothing. Also only 12 volts on both battery's tested with the meter. Jumped the starter switch and kill switch as well. Nothing. Any ideas???

[@toreedvardsen7993]

Did you find the problem? Got the same on a 2019 Exc tpi

[@bearbeau13]

@@toreedvardsen7993 loose wire in one of the plugs behind the number plate

[@bencook8700]

btw (not explained in video but check the fuses on the solenoid they might not be blown but check the oms corrosion is a big deal and i've been having that issue)

[@mattie_world]

Ben Cook will it still tick if the fuses are blown?

[@KTMinside.M]

Many tanks i fix the problem

[@Bellagracevlogs]

my ktm rc 390 2017 don't start just 2 clicks from solenoid I tried putting screwdriver across solenoid terminal and nothing no spark so what's it mean if no spark from solenoid brand new battery

[@Yuuiiytrfbh]

I took this e-start system apart and I may have put it back together incorrectly, I found an extra part that looks like a bushing 🤦‍♂️. Can I still ride it if I only use the kick start and not the e-start? Or will I screw the bike up? Thanks guys!

[@slaverace1]

Yes, use the kickstarter and you will be OK.

[@Yuuiiytrfbh]

@@slaverace1 thank you!!!!

[@Deep-Sarcasm]

06 450. Good battery. New fuses in solenoid. When jumping the solenoid it starts. But button does nothing. Took button apart, tried jumping, nothing. All wires look good from the outside. Brand new ktm ignition key switch about 4 weeks ago, worked fine until today. Any advice?

[@slaverace1]

Hello: If it starts when you jump the solenoid, that indicates it's in the button, switch or the wires going to the solenoid from the button/switch.

[@lewiswade5675]

Jeff Slavens when you say switch what do you mean ? I’m having the same problem starts when I jump the solenoid but when I press the button nothing

[@Tank2797]

Battery reading 13.8, no clicking, the starter turns when jumping the two wires at the relay. Changed the relay but still nothing. The fuses are ok. Is what’s left only the wiring?

[@mmaaddict78]

Check that the wires have continuity between each part in the system. Could have a break somewhere.

[@Jrod_FPV]

did you ever get it solved? if so , what was the problem? Sounds like you checked everything on the positive side... how about the ground side? Ground cables can get partially cut/ broken under the plastic on the connectors and you'd never see it unless you break off the plastic.

[@user-jx2nh4dd1m]

Hi Jeff. cant find a problem with charging..check all like manual, but charging to battery 13,-13,5 max....what can check else? may be can help to me

[@slaverace1]

It's always the stator that fails. slavensracing.com/shop/high-output-stator-ktm-husaberg-trail-tech/

[@user-jx2nh4dd1m]

Thank you! decide the problem change the battery, was short circuit and didnt give anough

[@gymclass_scooter7561]

i have a 2016 ktm 250xc and the bike turns over and has compression but it wont start it kickstarts fine though do you have any ideas???

[@dupiilatuk7697]

I do have a same problem

[@NCER999]

I have a good battery, hit the button and there is no click. when I jump the solenoid terminals the starter goes. should I be looking at the solenoid or the button??

[@willkelly937]

Tim Newman I'm having this same problem with my 13 200 XC-W, I'm going to try 2 new fuses in the solenoid. Hopefully that works cos I really don't want to buy a new solenoid.

[@PatrickDillonMoto]

Check your start button. bypass the button to see if fault still exsists

[@willkelly937]

Nope, fuses did nothing. Just replaced the solenoid which fixed that problem but now the bendix isn't engaging. sigh

[@joser402]

How do you jump the solenoid ?

[@TheSquad1112]

Hi mate fan from Australia I have 2019 250 exc tpi and I have a started problem. I have 13.3 volts at battery. When I push the button the solenoid makes no sound but if I put a screw driver across terminals it starts. So I thought it was the switch but it still same result. Do you think it might be the solenoid. You help would be greatly appreciate

[@slaverace1]

Hello mate, It's rare, but it sounds like your solenoid has failed.

[@TheSquad1112]

Thanks so much mate you’re a legend

[@dsleah]

any suggestions for me? my 2018 fe250 won't start. I can jump start it by pushing down a hill and it runs fine. It started after riding in the rain, the e-start button was working every other time tried it for most of the day But now I don't have anything when I press the e-start button. Ground and battery are good. Power running from battery to starter relay with main fuses and out of starter relay. Yet no power at kill switches or e-start or to fuse box. any ideas? Read more REPLY

[@dsleah]

when I jump the e-starter moter it does something but Ive got no power out of the solenoid/ starter relay on the black cable going down.

[@sonoma314]

Jump it with a screwdriver yeah, but it will spark considerably and scare you a little bit, I hope it didn't damage anything. Enough juice to make the screwdriver stick to the post. Mine was a broken wire at the white connector from the starter button to the harness. Those two wires a very thin, and not protected

[@Regan_Tatham]

Having minor issues with my 2013 ktm 200xc-w e start. Although the motor works fine sometimes the motor will just spin freely and not turn over the engine and other times it will work flawlessly. I think that its just a slipper clutch thats out of adjustment but am not quite sure. If anyone knows about these e starts i would like to hear from you.

[@slaverace1]

KTM 200s do not have slipper clutches. Spinning freely indicates the Bendix slavensracing.com/?s=bendix&post_type=product has failed.

[@Regan_Tatham]

@@slaverace1 Thanks I'll look into it

[@Aaron_Lasher]

I’m lost. I have a 2009 ktm 250xc. Just put a brand new battery in it. Everything’s clean. And I get nothing from the button. I tried to bypass the solenoid and got nothing with that either. Idk what the problem is.

[@slaverace1]

When you jump across the solenoid it creates a direct power source from the battery to the starter motor. If the starter motor does not turn over, it is toast. Time for a new one. slavensracing.com/product-category/electrical/electric-starter-system-parts-electrical

[@Jrod_FPV]

what ended up being the problem? Sounds like could be an issue on the ground side of the circuit.

[@Aaron_Lasher]

@@Jrod_FPV I ended up replacing the battery and what not. Turns out it was dead but I had some serious stator issues. That’s what everything ended up being and I replaced the relay I think as well. I might have had a bad ground as well I forget lol

[@TruenorthmtGod]

I've replaced my starter new starter works once then no good. Brand new battery. Battery is 13.5 I'm thinking clonoid .. I've replaced everything else bushings bendix. I get a click idk anymore

[@robbe0802]

it doenst't click when i press the button but it starts when i bypass the solenoit, does this tell me my solenoit is bad ? i don't really get it

[@dicklyle]

robbe0802 thats exactly what mine is doing,no click but when i jump it it turns over the starter.Fuses maybe?

[@robbe0802]

Dick L yes on my bike it was one off the fuses

[@dicklyle]

robbe0802 Im grabbing some tonight, thanks

[@risingeagle915]

So Jeff here’s my issue. I got 13+V in the battery and the starter relay is clicking and sending Volts to the starter but I’m only reading 9V at the starter with the cable installed. If I disconnect it I get 13+V. I have a brand new Neutron starter on it. What could be the problem? It’s a used bike I bought off someone that didn’t have the E/starter system so I bought most parts new except the Bendix and starter relay.

[@slaverace1]

Sounds like a starter motor issue. I've never heard of that brand.

[@risingeagle915]

Jeff Slavens so I installed a known good OEM starter and it’s starting a lot more than before but it still doesn’t start it at times (mainly when bike is cold or been sitting for more than a few minutes). Would a new 2014 CDI (bike is 2013) improve this intermittent starting issue since the 2014 CDI is suppose to improve the overall performance of the bike?

[@risingeagle915]

@@slaverace1 RMATV sells them.

[@slaverace1]

@@risingeagle915 Changing the CDI will not help starting, only performance. Does it turnover slowly or freely?

[@slaverace1]

@@risingeagle915 Makes sense. More junk from WalmartATVMC.com.

[@gatesshelby5200]

Thanks

[@slaverace1]

No problem

[@r.cic1596]

And what if a new battery that was put in 2 months ago is now drained and no good?

[@slaverace1]

If it is a lithium, then it most likely has a warranty. Reach out the the manufacture.

[@r.cic1596]

Jeff Slavens could it be the regulator? Had to use butt connectors to re wire plug was corroded and a prong snapped off so I cut and re wired 2017 300xc

[@haydenmosa655]

Have you ever had the starter button go bad?

[@slaverace1]

I have not but have heard of a few failures, although not a common issue.

[@johnnygalvan1344]

My battery is 12.9 v Is that bad ?

[@slaverace1]

Probably OK.

[@Globalbeast_]

Mine burn the fuses

[@simongill7560]

Bullshit I've repaired several bendix, its really easy!

[@Jrod_FPV]

what's the trick to doing it right? are you welding the gear to the shaft? / how are you doing it?

[@diydirtbike4625]

How?