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KTM starter motors 250EXC 300EXC 20082016 problems fixes amp repairs︱Cross Training Enduro
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Problems, fixes repairs for KTM starter motors on the 250EXC and 300EXC for 2008-2016. An introduction to the known issues and common problems with the KTM two stroke starter motors on the 200EXC, 250EXC and 300EXC along with maintenance and repairs. Problems include brushes, bushes, armature, crown wheel, bendix and we cover the Slavens wet mod as well as links to the starter motor rebuild vids from Slavens Racing - visit their website here: http://slavensracing.com/ The 250EXC and 300EXC are also called the 250XC, 250XC-W and 300XC, 300XC-W in the USA. KTM make great dirt bikes. So we'll cover just a few basics if you are having problems. Starter motor not working at all? Check your kill switches and starter button, KTM switches often corrode within a few years unless they are disassembled and cleaned regularly. But there is one glaring design issue with the two stroke range and that's the starter motors - a dodgy slapped on design that we suspect was outsourced to these guys. With the recent $1000 price hike many of us think it's high time KTM put a decent system in their smokers, as they did with the four strokes. Not all these starter motors will fail, in fact some guys get hundreds of hours in before replacing parts, but for others constant repairs can get very tedious. A no brainer but easy to miss, make sure your battery terminals are clean and tight, and the battery is fully charged. If you get a clicking sound, then your starter relay probably needs replacement. Take the plastic sidecover off and check the terminals on the starter motor. If your starter isn't working, you can put jumper leads directly to these terminals to see if the wiring or earth are the problem. Next we'll take the starter motor out. The starter brushes often wear quite quickly, as an the bushes. The screws holding the brushes have a nasty habit of corroding and breaking off when you try to undo them. This happened to mine, you need to then drill it out and use a self tapping screw. Or just buy a whole new starter motor. I won't go into too much detail here, as Slavens Racing have this excellent set of videos and also good prices on replacement parts. Check the shaft turns as sometimes the bearing seizes. Turning the shaft will feel a bit strange as the magnets inside do their thing. Water and dust are often known to get through that bearing too. See the Slavens vids, but things to watch for. Check the armature. Have the brushes worn through the armature's metal coating? Is the metal coating corroded? See the Slaven idler gear vid here for more on this. The bendix just sits in alloy bushes that are prone to wear so check those too. Water and muck can easily get into the starter motor, either through the bearing in the starter motor or the breather hole KTM put in the bottom of the stator cover. Are any of the magnets loose? Is the spline worn? A common complaint on pre 2013 Katos was the weak starter motor. The 350W was replaced with a 410W motor. But some have argued this can place extra strain on an already poor design, you be the judge. Now we'll pop off the next cover and look at the crown wheel. Make sure the teeth and fine, and the bush it sits in isn't worn. This can need shims to line it up correctly or the starter can have trouble turning over. Some do the Slavens wet mod, where you block off this breather hole and pour oil in. See this Slavens vid for more. 8 Check the bendix. It should spin freely, then turn the cogs and it should expand then lock into place. Early KTM bendixes were very prone to breaking. Around 2012 they supposedly fixed this, but they still only use a press-fit which still breaks... trust me I know this as my new one broke after only two rides and there's no warranty of course. KTM says they've updated the 2015 version to work properly but it can't be fitted to earlier models. I did manage to get mine repaired, google Fix repair for KTM 250EXC 300EXC starter bendix when the press fit buggers up for details. Do your research, some claim the wet mod created more problems than it solved although the evidence for this looks sketchy - most say it's helped a lot. Another enduro vlog from the gumbies at http://www.crosstrainingenduro.com • Playlist for our enduro vlogs: • All our enduro rides!︱Cross Training ... • Cross Training Enduro Skills Facebook: / cross.training.enduro.skills • Cross Training Enduro Skills Youtube channel: / @crosstrainingenduro Music: https://www.purple-planet.com • Music: www.playonloop.com • Music: https://soundimage.org • Music: https://audionautix.com/ • Music by Tobu: https://tobu.io / tobuofficial • Music: https://www.bensound.com/royalty-free... • Music: https://soundimage.org • Music by Atch: • SoundCloud: https://bit.ly/AtchSoundCloud • Spotify: https://bit.ly/AtchSpotify • Instagram: www.instagram.com/atchmusic
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