KTM300 starter motor?

[K6K]

The well known starter motor problems on the KTM 2 strokes has happened on my bike at 130 odd hours. I have treated it a bit more gently than I did on 4T starters, but mostly I just used it. Anyway Not long after I greased the bendix gears and cleared out the dirt in the stator cover (Ive done this 3 or 4 times) the starter motor had trouble turning over the engine. It turned over really slow - like it had a dead battery. I checked the battery and it was fully charged, and I had the same slow cranking using a car battery so I ruled the battery out as the culprit. Next I stripped the starter down and found that the brushes were really worn so I replaced them. The rest of the motor was gummed up so I cleaned as much as possible with electric motor degreaser.
The brushes dont seem to have been the problem as after reassembly it still cranks really slowly - much to slowly to start the bike. When it is not connected to the bendix it seems to crank over with some speed but as soon as it is loaded up it doesn't seem to have any torque.
After some googling I found a similar report that stated the bushings that held the bendix gears we worn causing it to 'skew' under load. I don't think this is the case with mine, I have checked wear on the gears as per the manual and it looks OK.
Any ideas on what I can try next before I take the pain and order a new one? They are between $270 to $300 in the US...I shudder to think what it will be here.
- Any further tests I can do on the motor?
- Anybody know of somewhere I can take it to get it tested?

thanks

[flyingcr250]

we have the same problem with electric window motors, they work fine on the bench but when load is applied they dont work properly or are down on power, usually a new one is required

id just take the motor to an auto sparky, they might be able to tell you if its pukaroo or not

[xrtim]

My '09 300 exc has the same issue. Did you try a new motor?

[K6K]

My '09 300 exc has the same issue. Did you try a new motor?

I got a new motor but have not tried it yet (enforced riding break due to injury)

[Taz]

I would try kick starting it ya soft bastid

[nigele]

Agree to just kick, but if it is on the bike then you should be able to use it. And very handy if you get a numpty stall in front of you going up a hill and forces you to do the same. Press the button and off you continue...anyway I digress and to the point of me commenting on this post.

How did you resolve this issue on the 300? Di you have to replace the starter and the bendix or did you just service them and then do the wet system upgrade? And the second part of this where did you source the parts from? Did you get them in NZ and if so was t for a big premium or did you source from the US e.g. Slavens?

Cheers

[IIIRII]

I tried the new brushes thing also, and it didnt fix it.


I just imported a KTM Starter motor from EMS global Direct
$201 us + freight ($50) / $320 NZ delivered to my house , took about 7 days , very good serrvice and I would recommend them.

The cheaper way would be to buy the armiture kit which comes with everything to go into your starter case (us$ 100) I think


KTM NZ want $685 + gst $787.00 For an e start motor, this is just a blatent RIP OFF / when you can buy a geared car starter motor for under $200 NZ , KTM are just taking the piss charging $800 for a started motor half the size of a car one.