KTM, Husky & GasGas 2Stroke EStarter Inspection and Maintenance

This video show a procedure to inspect and maintain the electric start system of KTM, Husqvarna and GasGas 2 stroke model, including TPI. The bike in the video is a 2021 KTM 300 EXC TPI.
KTM & Husqvarna 2-Stroke Electric Starter Issue Debug: • KTM & Husqvarna 2-Stro...
KTM & Husqvarna TPI OEM Kickstart Kit Installation: • KTM & Husqvarna TPI OE...
XRC Bronze Starter Bendix Bushings: www.tokyooffro...
2021 KTM 300 EXC TPI with RK TEK Head & GET ECU Race Kit
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Facebook: / tokyooffroad

[@richkay228]

Just an fyi i proactively bought the XRC bendix bushings for my '24 300 xcw with 3 hrs on it. I tried removing the bendix without removing the flywheel and it can't be done. So your comment is valid that if your bendix can be removed without removing the flywheel than your bushings are worn. Excellent informative vid !

[@mikeburnett6222]

Mark, you need to upload a newer video for the 2023 / 2024 bikes. I believe one must remove the flywheel from the new version. Let me know if you have found this different. 😊

[@TokyoOffroad]

Good idea. I have already fitted XRC bushings on my 2024 KTM 300 EXC and removed the flywheel as it seemed very tight to remove the bendix with the flywheel in place. I'll make a new video...

[@mikeburnett6222]

@@TokyoOffroad I’m doing my bushing and upgrading to a larger output stator.

[@stevebaum]

Thank you, I save all your videos for my KTM maintenance. I appreciate your attention to detail and clear explanations. 👍

[@TimoTurner]

When you inspect the starter solinoid, its worth checking the fuses in the clear plastic caps. I have seen the caps full of water! I think one side is the 'live' fuse and the other is a spare.

[@rl7880]

Man, your videos are soooooo helpful. Thank you. I love your channel.

[@aaron1278]

Best in the game can alway rely on you for good info video !!

[@TokyoOffroad]

I appreciate that!

[@bannedbrothers]

Mark, another informative and educational video. I’m now in the Pacific Northwest in Washington so I need to make sure my connectors are clean and dry and use dielectric grease. Thank You!

[@09MrDuke]

This lad is AWESOME. I have a 2021 Sherco 300se (2T) but ALOT of his stuff is helpful/relevant for m bike. 👍

[@TokyoOffroad]

Great to hear!

[@Enduropnz]

the thread locker is great for fixing the bushing

[@jerseyjeeper1575]

I’ve got those XRC covers and bushings. They are top shelf quality. Highly recommended!

[@mskouwa]

XRCのSTARTER BUSHが届きました～ベンディックスのトラブルが少なくなりました。また、宜しくお願い致します

[@TokyoOffroad]

Pleased to hear hear that it is working well now. Thanks for your business

[@sethwaterfall]

Great video! Thanks for doing them.

[@Cee-FJedi]

Another top video and super useful thanks.

[@3dmick1]

Love your videos great work mate 😀

[@DeanHickman-g3s]

Hi love your chanel, have learned alot, just a tech question, i have installed a lectron, v force 4, and a s3 low compression head, i live at sea level, my question, would i need to adjust the metering rod, greeting from Wild Coast south africa👊

[@TokyoOffroad]

Pleased to hear that you enjoy the videos. Regarding adjusting you Lectron metering rod, that would depending on whether it's currently running well or not. Take it for a test ride and see how it performs, then decide whether it needs adjusting.

[@DeanHickman-g3s]

@@TokyoOffroad bike ran sweet before, still does but seems a little richer which i think is good, so will go on a long ride and decide, i just wondered if the head may change the richness👊🤣

[@Danman1972]

Every KTM I've owned has issues with the starter connection behind the headlight. Water pools in that connector from the top around the wires and rots the wires. Fill those the pin area with grease as well as those holes and wrap some electrical tape around it. Just got a new TPI and will be doing this as it has no kick starter. I guess I will need to add a small jump pack to the camelbak and SAE dongle to the battery tucked in the air box as well.

[@gohvahn]

I got husqvarna tx300i 2022 . Sometime it’s start easy and sometimes don’t . But just need to push a bit forward or back will start again . Wonder what might be the problem, I’ve check start switch and kill switch clean . Battery no problem. What might be the problem? Thanks 🙏

[@graid9275]

Hey Mark, very informative video as we expect no less from you. I know I have asked a few times but are you still going to continue your engine build series?

[@TokyoOffroad]

Thanks. Yes, I plan to make a video (installing the 300 kit) in the next week, or two...

[@RourkeMcgriskin-wv7et]

Hello I’m having a big problem with my 2023 ktm 250xc 2 stroke flywheel. Sometimes when I start my bike my flywheel misadjusts, causing the ignition timing to be off and not start the bike. I’ve tried tightening the nut to spec and using the locktite washer and red locktite liquid. Still comes loose. The nut and the flywheel stay tight but it misaligns the flywheel. This is also my 2nd flywheel as my first flywheel stripped completely. I don’t know what to do I’ve tried a bunch of stuff and I’m thinking of either impacting my nut on or welding it.

[@TokyoOffroad]

You must be missing the Woodruff key. Remove the flywheel and check that the woodruff key is installed and has not sheared.

[@goodboyringo9716]

Always great video and info from Tokyo Offroad

[@joejohnston471]

Mark, Any good option for removing the bushings without the puller?

[@chestertownelectric6290]

Pack the bushing with grease, insert a shaft, punch, or bolt that slips in with very little gap, and hit with a hammer. It’s piston-like effect pops the bushing out.

[@Mrdirtbiker01]

Do most new enduro bike have the same poor wiring quality with no water seals on most of the starter and lighting circuits? Was shocked to see on my new ktm300exc 22. Working on modern cars all wiring I work on is sealed. Unless In a sealed box or in the interior

[@Erikenduro]

Coul you put a small amount of oil inside the cover ( say 50ml) to keep everything lubricated ?

[@chestertownelectric6290]

What happens if you accidentally hit the start button while the engine is running? Does the bendix engage, get stuck, and over rev the starter? Maybe start buttons should have a flip-up protective cover. Someone could sell a harness kit with water-tight connectors.

[@TokyoOffroad]

Pressing the starter button while the engine is running should be avoided. Typically the bendix will not engage. If if the starter button is continuously pressed, or gets stuck it might engage, which may result in damage to the bendix and possibly also the starter motor. The 2024 KTM 300 EXC TBI I have has a 6 pin weather proof connector for the starter/run/kill switch, which is a big improvement from the old style 4 pin Molex connectors.

[@space_invader]

Thank you for this, very helpful. I followed your instructions and thought I got the issue fixed by changing Bendix and bushings. But problem not solved, still does not start. Opened starter cover again, pressed ignition button and starter motor does not turn fast enough to allow bendix to come out and play with the flywheel. Is this normal when the cover is off or should the bendix engage with flywheel if starter motor spins fast enough? KTM 300 XCW 2018.

[@TokyoOffroad]

Possible causes of the bendix not spinning fast enough: 1) Bendix gummed up (but you have fitted a new one so probably OK) 2) Bendix bushings are bad (again you have new ones so probably OK) 3) Battery voltage is low. Make sure you have a good battery and it's fully charged 4) Ground connections are not good, particularly the battery ground strap to frame connection. Check and use a wire brush to clean any oxidation. Use dielectric grease, or silicone grease to help prevent future oxidation. 5) Starter motor is going bad. Some people repair themselves (clean out and replace brushes). Or buy a new starter motor and replace (motor needs to be lifted up from the frame (or removed from bike) to replace the starter motor.

[@space_invader]

@@TokyoOffroadThanks, I appreciate your quick response. I think you confirmed that my issue is the starter. I put a tickle charger on the battery when I test and check I'm at the right output. Followed your video step by step...cleaned and greased everything and no success. Unfortunately, the starter doesn't come off the engine (with engine in place) by just few millimeters! Will do the work during the winter and change piston at the same time. Thanks again!

[@zrodimel]

When you say "lightweight oil", what do you recommend?

[@krp6147]

Great stuff thank you 😎👍

[@gotdirt66]

Are their more stout starters than OEM KTM ones. At 70 hrs my starter is having issues. I had the kick starter and Rekluse torque core drive manual.

[@TokyoOffroad]

I don’t know of any 3rd party starters which are tougher than OEM. I personally haven’t had one fail. They will be more prone to failure if the system isn’t maintained, especially if the Bendix bushings aren’t in good shape (in extreme cases they may cause the the Bendix to become jammed and then the starter motor will burn out).

[@michael397]

there is a little hole below the starter should seal it, my starter burned water come inside from there change the starter is hell work......

[@TokyoOffroad]

That’s a tough one to answer. The hole is there to drain water if it finds it’s way in. If the hole is the only way in then probably no problem, but it water can find another way in then blocking the hole would make things worse...

[@michael397]

@@TokyoOffroad the real problem is change the starter soooo tough..... who designe why?

[@TokyoOffroad]

@@michael397 - Yes, I agree, it's a PITA to change the starter motor. I guess I'm lucky and haven't had a starter motor failure so far. I don't do many water crossings which is probably a major factor...

[@andrecontois8510]

Not to be a debbie downer but loctite closes dirtbike trails same with Camelback don't support them. Nice video!

[@at1asru]

Very nice man! Keep it coming!!

[@enduroa.k.o]

Great information thanks 👍

[@bmx08897fitbikes]

Some times I engage my started and I just spins like it’s not catching the fly to crank the motor what would cause that

[@TokyoOffroad]

A if the bendix becomes sticky internally that would cause it to just spin and not engage reliably. Or if the bendix bushings have gone bad. Or if the battery voltage is low, or ground connections not good.

[@johnchafin3817]

Where can you find the ignition cover?

[@TokyoOffroad]

Either direct from XRC, or I'd be happy to order one for you. I don't list them on the Tokyo Offroad webshop because it's possible to have a custom design on the covers. If you'd like to discuss you can contact me here: www.tokyooffroad.com/contact/

[@boogiman007]

Where do i order the XRC ignition cover from ? i need one , and can't find them.

[@TokyoOffroad]

I don't stock the XRC covers in the Tokyo Offroad webshop as they can be ordered with custom logos. Either order directly from XRC (can contact via their Facebook page), or I can special order for you: www.tokyooffroad.com/contact/

[@musicbox4022]

Where do I buy the xrc covers? I couldn’t find them on your site

[@TokyoOffroad]

Directly from XRC in New Zealand, or you can order through me if you like. I don't keep them in stock as it's possible to have your own logo design. If you'd like to discuss you can contact me here: www.tokyooffroad.com/contact/

[@GeniusEnis]

I have searched for prices and where to buy the Xrc ignition cover but I haven’t found anything than their facebook site really. How can I buy a cover like that? Thanks

[@TokyoOffroad]

Thanks for your interest. I don't keep the XRC covers in stock in the Tokyo Offroad webshop as it's possible to have your own logo design. But I can order and ship one to you. If you'd like to discuss please contact me here: www.tokyooffroad.com/contact/

[@MrJasonfromcanada]

My 2017 xcw is starting to spin and not engage periodically on the trail

[@TokyoOffroad]

If the bendix doesn't spin quickly enough, or it is sticky you may experience poor engagement. A few things to check: Battery is good and fully charged, ground connections are good, bendix is not gummed up internally and sticky and bendix bushings are in good shape.

[@MrJasonfromcanada]

@@TokyoOffroad I watched your previous video on this issue and will start with the visual inspection. Ive had the issue since it was new, but would only happen once in awhile. Now with 170hrs it doesn’t engage more periodically especially on the tough trails where im constantly going over and stalling on logs, and root step ups and such. Thanks for the info on this.

[@TokyoOffroad]

@@MrJasonfromcanada - My 2017 was the same when it was new. I removed the bendix, cleaned it out internally with some parts cleaner spray and blew it out with compressed air. I then lubed it up internally with some light weight oil. It fixed the issue. However after 170H I suspect that your bendix bushings will not be in good shape and will need replacement

[@MrJasonfromcanada]

@@TokyoOffroad well I did an inspection today and the oem bushing came out with the bendix. Where the bushing sits has worn a slight oval but hasn’t cracked like in your previous video. Looks like I’ll be ordering a new cover and bushing. Appreciate your tech videos, I would have never thought to look there. Fortunately there is no wear on the bendix teeth.

[@keithwimberly5779]

Do you sell the XRC Ignition Covers for 2020 KTM 300xcw ?

[@keithwimberly5779]

Sorry I found the information below

[@TokyoOffroad]

@@keithwimberly5779 - Thanks for your interest and email. Yes, but I don't keep stock as it's possible to order the covers with custom logo designs.

[@moto3moto419]

Ktm, that Chinese bike build quality . R and D on reliabilty and quality control continues to be non existent.

[@EricNeilson_]

"or replace the case" ... ouch

[@TokyoOffroad]

Yes, and for that reason it is a very good idea to do a periodic inspection of the starter system (including the bendix bushings) even if the e-start appears to be performing fine. I know many perform no maintenance until the e-start stops working and it can get expensive if the crankcase needs repairing, or replacing...

[@joeedwards627]

How does motorsports affect the starting? It either starts or not, nothing to do with how you ride it! Sorry not aimed at you.. Ktm!

[@TokyoOffroad]

Yes, I agree with you on this. Either way it’s a good idea to perform starter system inspection and maintenance at regular intervals.

[@taegansilva1829]

second!!!!

[@human1513]

KTM's seem to have poor electric wiring, connectors & casings. They could learn a lot from Japanese bikes. Exposed starter button connector under the too triple clsmp is not a water sealed connector!!! Are these bikes being built in 1910 by children? I am disappointed in KTM's low quality after owning my 1st KTM for only 2 weeks. Very high maintenance machinery. If it leaves me stranded I will burn it right on the spot.

[@TokyoOffroad]

Yes, some of the electrics could very easily be updated by KTM with more reliable/higher quality connectors, switches and wiring. I’m not sure why they don’t do so as many people have problems and the cost difference would not be great. Like any brand KTM have plus and minus points. In many of my videos I focus on the minus (problems) and hopefully provide enough information to make your riding more fun with less chance of problems while out on the trail. Regarding Japanese bikes none of the manufacturers have estart 2-strokes so they are not an option for many people (who don’t want to kickstart). Compared with KTM the Japanese bike do tend to have better electrics, but in my experience worse mechanical longevity (need much more frequent top end overhauls) and worse brakes and clutch. I rode Honda CR 250 2-strokes for a long time (sadly no longer made) so have a lot of experience with them…

[@human1513]

@@TokyoOffroad I got a little worked up. Sorry for going so far with it and appreciate your patience and tutoring. I have had great luck with 99% of my Yamaha and Honda offroad bikes over my +40 years of riding. Almost as good were my Superbikes I raced and streetbikes. I just sold a 2015 Yamaha YZ250 I used for offraod riding. It worked flawless. Note I take good care of all my bikes. Stored in unheated garage always. Washed and cleaned after everyday of riding. Oils changed, cables and linkages lubed,.... My most favourite bike of all time had gobbs of torque, was 12 pounds heavier than a 250 cc as I recall. I could putt all day long then open it up and it ran like a scared cat. It was a 1996 Honda CR500. Used to ride it non-stop 6-9 hours most Saturdays and 6+ hours Sundays during the spring, summer and fall. It never gave one once of trouble no matter how deep the mud (seat height) or how much it rained. I got the KTM because a few short years ago I had an accident and broke +15 bones, including both pelvis's, leg, collar bone, pulled all those muscles? off that are attched to the sides ot the spine. Like in the movies I had to learn to walk again after surgeries. I realized now I literally have more hardware in my mid supsension area (pelvis, hips,..) than my KTM does. LIterally plus 5 lengths of chain. As a rsult I have a lot of difficulty obtaining the range of motion to get a leg up and over a bike and then to kick start it is, well , I imagine it is entertaining to watch. Never giving up I opted for a bike with a cheater button. A KTM with a starter button. Oh my left leg is now 2.5 cm shorter. I think I will look into replacing with a sealed connector the starter button connection as a place to start. Lots of automotive connectors to be had online plus for boats and motorcycles that are sealed units. I have never had a motrcycle let me down on a race track, 4,000 km road trips or all the trail riding. Oh a superbike did stop once due to the used ECU's circuit board cracking on the back stretch. Long push back to the pits. I took it apart and with a magnifying glass identified the hair crack. Soldier repaired it and it was good after that. Thanx for all you teach us.

[@TokyoOffroad]

@@human1513 - So sorry to hear about your accident, but pleased that you are back on a bike. The older we get the less fun it is to kick start bikes, especially when on the side of a steep hill!

[@Mrdirtbiker01]

Total agree. I was really excited getting my new bike. Discoverd it rerouting some wiring not fitted correctly and was like wtf No seals. Was shocked. I’m sure most ktm bikes will have water ingress after a few years with some corrosion. Im sure they did that on purpose so they don’t last that long. Doesn’t make sense to me. Would love to chat to the electrical engineer for the reasons behind it.

[@TRIVANDRUMBASEDKERALITE]

First... 👍