KTM xc/xcw starter issue
Posted: Wed Jan 03, 2018 11:17 am
Posting up quick tech write up on a repair, temporary at this point, to an issue I encountered with the starter system on my 15 XC.
Other years 08-15 XCW and XC similar, haven't seen this issue covered here yet (quick search).
Symptom: Random starting, in neutral only, lots of noise and hard ugly stops of the starter assembly, and forget cold cranking it...
So, pretty much all systems normal for a KTM starter.
~86 hours on the bike, new to me.
Decide to take a look at the usual suspects. Wow this thing is definitely an afterthought and cobbled together, so much gear friction it needs the reduction to even turn the motor over, at a blistering 60rpm.
Removed the starter motor. Turned over smooth and on 12V bench test ran good.
Remove ignition cover to inspect bendix gear.
Shrapnel everywhere, dried grease, grit n bits, metal shards on pickup and had been abrading the stator epoxy.
Bendix works ok by hand and smooth.
Bushings looked ok, but dry, except the outer bendix support bushing; completely MIA the gear had been chowdering out the cover bushing pocket, misaligning the bendix mesh.
Well, there's your problem right there buddy.
Called for a new ignition cover, but given the holiday break, cover wont be in until January, and I wanted to ride.
Note: Cycleworks was open and normally stocks one cover as this is a common issue, but had sold it, and was waiting on one.
They did have the sorry little pieces of junk KTM calls bushings ($2 ea), so I grabbed a few as "consumables" in anticipation of the new cover arriving, and these wearing quickly.
I could've just removed the starter gearing, sealed the starter input, and replaced the cover, making it a kick only for the ride, but the MacGruber in me was too strong to subdue...
And it was -30 and I had a few days. And I paid for e-start dammit. Nothing to lose, so...
Filled the pocket flush with Permatex "steel" type epoxy (covered stator/pickup in case). Let it set under mild heat ~8 hours, then somewhat carefully center punched it and drilled it. Maybe should've set it up in the drill press, but such a fine Austrian design didn't seem to merit that level of precision.
This stuff was soft, maybe it needed longer to set, or was just janky. BUT IT SAID GOOD FOR 4000 PSI IN 4 HOURS ON THE TUBE??? NOOOOOO!!!
Piloted it, then stepped up in drill sizes until the OD of the bushing (again, that's a strong term) was reached, made a bit of a bottoming bit by grinding the last size drill bit nose off and bottomed out the new epoxy bushing pocket.
Tapped the "bushing" (again, harhar KTM) in, and set the bendix in and measured the standoff from the case edge, and checked that against the case bendix output support on the bike, to ensure that re-installation didn't crack the cover.
Did the Slaven's YouTube clean and greasing, reassembled it all.
Laser temperature of engine case 5C, cranked the starter and it fired up, with only "normal" KTM starter noises, ie: crankcases full of marbles.
So far haven't had to kick it yet, even during the whole ride, it was used very frequently (ride is a strong term given conditions), so maybe its holding. Or perhaps the ignition is now full of bushing and epoxy. Find out when the new cover shows up.
Anyhow, if you have one of these superbly engineered starter systems , hope this helps out. Definitely inspect and clean and lube regularly.
Other years 08-15 XCW and XC similar, haven't seen this issue covered here yet (quick search).
Symptom: Random starting, in neutral only, lots of noise and hard ugly stops of the starter assembly, and forget cold cranking it...
So, pretty much all systems normal for a KTM starter.
~86 hours on the bike, new to me.
Decide to take a look at the usual suspects. Wow this thing is definitely an afterthought and cobbled together, so much gear friction it needs the reduction to even turn the motor over, at a blistering 60rpm.
Removed the starter motor. Turned over smooth and on 12V bench test ran good.
Remove ignition cover to inspect bendix gear.
Shrapnel everywhere, dried grease, grit n bits, metal shards on pickup and had been abrading the stator epoxy.
Bendix works ok by hand and smooth.
Bushings looked ok, but dry, except the outer bendix support bushing; completely MIA the gear had been chowdering out the cover bushing pocket, misaligning the bendix mesh.
Well, there's your problem right there buddy.
Called for a new ignition cover, but given the holiday break, cover wont be in until January, and I wanted to ride.
Note: Cycleworks was open and normally stocks one cover as this is a common issue, but had sold it, and was waiting on one.
They did have the sorry little pieces of junk KTM calls bushings ($2 ea), so I grabbed a few as "consumables" in anticipation of the new cover arriving, and these wearing quickly.
I could've just removed the starter gearing, sealed the starter input, and replaced the cover, making it a kick only for the ride, but the MacGruber in me was too strong to subdue...
And it was -30 and I had a few days. And I paid for e-start dammit. Nothing to lose, so...
Filled the pocket flush with Permatex "steel" type epoxy (covered stator/pickup in case). Let it set under mild heat ~8 hours, then somewhat carefully center punched it and drilled it. Maybe should've set it up in the drill press, but such a fine Austrian design didn't seem to merit that level of precision.
This stuff was soft, maybe it needed longer to set, or was just janky. BUT IT SAID GOOD FOR 4000 PSI IN 4 HOURS ON THE TUBE??? NOOOOOO!!!
Piloted it, then stepped up in drill sizes until the OD of the bushing (again, that's a strong term) was reached, made a bit of a bottoming bit by grinding the last size drill bit nose off and bottomed out the new epoxy bushing pocket.
Tapped the "bushing" (again, harhar KTM) in, and set the bendix in and measured the standoff from the case edge, and checked that against the case bendix output support on the bike, to ensure that re-installation didn't crack the cover.
Did the Slaven's YouTube clean and greasing, reassembled it all.
Laser temperature of engine case 5C, cranked the starter and it fired up, with only "normal" KTM starter noises, ie: crankcases full of marbles.
So far haven't had to kick it yet, even during the whole ride, it was used very frequently (ride is a strong term given conditions), so maybe its holding. Or perhaps the ignition is now full of bushing and epoxy. Find out when the new cover shows up.
Anyhow, if you have one of these superbly engineered starter systems , hope this helps out. Definitely inspect and clean and lube regularly.