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  #1  
Old 29 Mar 2009
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KTM Electric start problems

Hi all,

I have a 2003 KTM 640 Adventure, about 5k on the clock. The battery was replaced a few weeks ago (just before i brought it). I am having a problem with the starter motor not turning over - The relay clicks - but it is like there is not enough power to turn it over. Now I would just charge it and see if that fixes the problem. But it was working fine all week (in the dry) but now in the rain it is not working.

Does anyone know what this could be or a way of finding out.

Thanks in advance for any help with this,

Morgan
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  #2  
Old 29 Mar 2009
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Hej,

check battery voltage with a multimeter.
Should be 12,80 volts minimum.

If not - recharge, check all connections at battery, starting relais and starter motor - also ground connection to engine. Look for corroded connections.

If the bike starts after that, you should check the charging power to the battery delivered from generator/regulator.

If the starting motor still not turns, you can connect the two poles at the relais(one comes direct from the battery, other goes to starting motor) by using i.e. a thick screwdriver. Turning motor means a bad relais then.

Not turning starter means to take it out and check it - but most likely battery/power/connections/corrosion fault or bad relais will cause your problem.

Good luck
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  #3  
Old 29 Mar 2009
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Does it turn over if you pull the decompression lever? If it does, then the problem is not enough juice - if not, it may be a problem with the starter.

edit: when I have no juice and try the estart, the speedo unit goes crazy. Is yours doing this?
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Last edited by KTMmartin; 29 Mar 2009 at 18:11.
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  #4  
Old 29 Mar 2009
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well I guess you are all wrong.... stop using the E-starter immediately before creating more damage !!!

learn to get use to the kick starter... at least for a wile... until you have the dosh to fix the problem in a decent way !!
now I had this problem starting a few years ago, and it's not the battery at all, it's the "free wheel gear" on the right hand side of the engine behind the ignition cover !

This gears are worn out and if carrying on cranking by E-starter coursing even more and expensive problems than kicking the bastard in to live.

The repair cost around £280 for parts and labour !

as I say it's not to bad to kick, done it for two years, done two trips to Scandinavia before I had the money to let it get fixed by a KTM workshop.
Actually it's a perfect example why it's importand using a bike that still has a kick-start for long distance travelling or low budget... you don't necessarily need a E-start at all.

well a tip for easy starting a LC4 by kick-starter:
hold the compression leaver and wind the engine with the kick-starter twice, than slip the compression leaver until the crank stops and "klicks in" !
after that pull the compression lever one's more, wind the kick-starter only halve way down, slip the compression lever, let the kick-starter move up a bit and give the bastard a good kick. that way your engine should start very easy even if cold or in winter....

good luck
spooky
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Old 31 Mar 2009
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Thanks for the replys everyone,

I am going to give a go at charging the battery fully (incase it was left to stand before sold to me) and see how it goes for a week and if it is running out. - Spooky, I will look into the free wheel gear, hopefully its not that bad.

Thanks for the hints with kickstarting, I wasnt completely sure how to use the compression lever but got it down now!

When i get it sorted I will post up what was wrong incase anyone else has the same problem

Cheers,
Morgan
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  #6  
Old 5 Apr 2009
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Morgan,
check the main fuse, the 20 amp near the battery to make sure the contacts on the fuse legs are tight. On my '02 Adv mine loosened up and I had a problem like yours. Does everything elsework when it won't start?

bill
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Old 5 Apr 2009
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Hey Morgan,
good luck on your trip,
say hi to George for me,
small world
Kev
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Old 20 Apr 2009
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Cheers Kev, cant wait.

Just to finish up this really, I checked the electrics with a multimeter, made sure the battery was charged. all were fine. problem is in the starter motor. One of the brushes has got stuck and worn down so it was not making the connection. for now I have un stuck it but it is a temp fix. so i need some replacement brushes but talking to local KTM dealer I cant buy them seperate to have to fork out for a whole new motor..

I am going to look for a KTM being broken or something and see if i can get hold of some .... but does anyone know if you can get the parts from anything else ( ie are brushes a standard size so could they be brought from somewhere else?)

Cheers again for all your suggestions

Morgan
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  #9  
Old 20 Apr 2009
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Same as Bill!!

Bill ShockleyMorgan,
check the main fuse, the 20 amp near the battery to make sure the contacts on the fuse legs are tight. On my '02 Adv mine loosened up and I had a problem like yours. Does everything elsework when it won't start?

bill


I have a 2002 KTM 640 and had the exact same problem. You try to start and the display just goes dim. No power. But when I wiggled the main fuse a little the bike had no problem starting....until next time.
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  #10  
Old 5 May 2009
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Quote:
Originally Posted by sarkbiker View Post

I am going to look for a KTM being broken or something and see if i can get hold of some .... but does anyone know if you can get the parts from anything else ( ie are brushes a standard size so could they be brought from somewhere else?)

Cheers again for all your suggestions

Morgan
Yes, the brushes are a fairly std size, I've replaced mine, just take the starter motor to an auto electrician & they will be able to find some that fit & install them for a fraction of the cost of a whole new unit. If you've got a soldering iron it wouldn't be hard to fit them yourself.

Cheers
Clint
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  #11  
Old 21 May 2009
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Clintnz - cheers, did that. they made up some brushes fitted them and gave me a spare set for less than quater of the price of a new S-motor

all seems to be working now. still not sure what made one brush wear more than twice the speed of the other one?!

Thanks all.

Morgan
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  #12  
Old 13 Dec 2009
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KTM 640 Bloody start not!

Hi, I have what I think is a similar promblem with my KTM 640 SM , Have bought new battery , that aint happening . When you try the estart there is just a click sound from side pannel area. Is this a fault with these bikes? How do I sort out. Very hard to kick! And no I know how to kick a bike! Any help please? P.s riding the bike a while ago and the back sprocket decided to shatter! that was fun. Well I'M still here waiting a reply. cheers Si
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  #13  
Old 20 Dec 2009
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Sounds like a similar problem to Sarkbiker - a motor problem.

The clicking you hear is the relay. We found upon dismantling the motor - very easy, that the earth wire inside had become frayed. Easily fixed with a bit of solder.

The motor is very easy to remove - 2 bolts and a wire and it will knock out. 2 more bolts on the motor and it will come apart with a little pull.
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  #14  
Old 19 Jan 2010
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ktM 640 Bloody start not!

Thanks , will give it ago. Will let you know. cheers simon
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