Owned a starter and alternator shop for 25 years. I compliment you on your video, very well done.

My 2020 tpi starter failed to light up when the button was pressed. Found chafed and shorted wires to the button where they were kinked and zip tied to the warning light harness. This was done at the factory and was inside the plastic wire conduit. This failure happened intermittently, last time in a tight sand wash 15 miles from a transfer rd. Luckily it failed in the shop when I could then track it down. Thank you for all the really great how to videos. I will be using your kickstart install video when it’s top end time at 150 hrs

From the USA, Cheers Mate!

Inspired by this video, I opened the starter button switch as well as the 4-way connector. It is surprising that the connector halves are 'open' from the rear, hence upon reassembly I chose to stuff the openings with silicon paste to make them watertight. There was indeed turquoise corrosion in the bottom pin (in my bike the connector is in vertical position; 2018 Husky). Using contact cleaner and a wire brush (male pins) and a 2mm drill bit (female connectors) managed to clean them spick-and-span. Normally I'd be hesitant to apply dielectric grease on connector surfaces - the grease being an insulator. But since there is only intermittent and short term low current going through to the relay, I gave it a go. Surely it will help keeping the connector free from corrosion.

Excellent information. Thanks

Nice bushing and great ideal. I commended for the good work you do and selling this bushing . KTM should be ridiculed for installing a week bushing like it does on a 10,000 bike.

I need help!, how can i warm up my withum battery (no headlight, fan switch) Maybe a cable around the headlight area that i can use to plug in a computer fan or something?

I don’t have any starter motor issues with my Husky TE 250 2015 as I removed it completely to reduce weight. I use that kick starter which exist in that motorcycle from the factory. I don’t ride any hard enduro with it. Mainly motocross type riding only.

First thanks for the video! I have a 2010 Ktm 300 exc. The starter will engage the flywheel briefly then spin without engaging? I’ve rebuilt the starter motor, new brushes, bushes, fully cleaned bendix and oiled with light oil throughout, battery is good 13.2v, even tried new ground from the starter to the frame but still the same issue? Any help appreciated

at 15:00 you mention the spare fuse underneath the starter relay and the other fuse which powers all the other stuff apart from the starter motor. As per the electrical diagram, as far as I can read there is no inline fuse for the starter system; can you confirm is there no fuse in the starter motor circuit ? An aside to the starter debugging process, the other three relays behind the starter motor relay, not applicable for this discussion but be good to know which each one does. Overall, your videos are always top quality and very informative. Thank you.

@TokyoOffroad

3 жыл бұрын

That’s correct, there is no fuse for the starter motor. The fuse powers the rest of the electrical system. On carb bikes it’s a 10A fuse and TPIs it’s 20A. The fuse is shown inside the starter relay in the circuit diagram.

Thank you for a highly informative video! Are there 'short' bronze bushings available for the 2017-18 models?

@TokyoOffroad

2 жыл бұрын

Pleased to hear that you enjoyed the video. Yes, an XRC bronze standard bushing length kit for 2017 bikes is available here: www.tokyooffroad.com/product/xrc-starter-bush-kit-250-300-2t-2017/

Hey mate great vid but it is not conclusive. I got lucky stumbling on to the fix for my starter. I got the clicking sound and nothing else. Turns out the previous owner installed an aftermarket clutch cover and the bolt near the brake pedal tip had a 60mm bolt instead of the required 55mm. The longer one goes through the end of the bolt hole then pushes up against the starter housing which is enough to distort it and seize the motor. Replacing that one bolt has fixed my issue.

@mattnean54

2 ай бұрын

Hey mate just wanted to say I had this issue to after installing aftermarket clutch cover. I was tearing my hair out going through this list when I saw your comment, much appreciated, bike started right up

@ian9toes

2 ай бұрын

@@mattnean54 awesome mate, glad to have helped out.

Mine spins up then all of a sudden stops but continues wind, almost like the battery doesn't have enough juice so doesn't throw the bendix out, i have xrc bushes good connections, thoughts?

@TokyoOffroad

3 жыл бұрын

It might be an issue with your bendix. From the factory grease is used to lubricate the flywheel and gears. The grease gets flung off the flywheel almost straight away and some may have made it's way into the internal part of the bendix, resulting in sticky operation and poor engagement. You could try taking the bendix out, spray plenty of parts cleaner inside it, blow it out with air, then use some dry lube to lubricate it internally. For gear and flywheel lube I prefer using a light weight oil which doesn't tack up. Other things to check are your battery is in good shape and fully charged and the battery connections and ground connections are good.

Went for a ride today on My 2018 tpi it was quite cold ( about 0 degrees Celsius) when I got home and parked the bike up I noticed it was waking itself up periodically ( like the sort of noise it would make if you left it on a hill in gear and it rolled forward a bit). I disconnected the negative battery terminal just to stop it from happening. Then later on I went to reconnect it and as I was screwing it in the bike woke up again and the connection started to spark. Any one got any ideas?

Does anyone have a source for the starter motor brushes on the 2017+ bikes yet? They must be serviceable like the older ones surly. (Yes I mean “Brushes” not bushings before anyone comes at me saying the bushes have been mentioned in the video)

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

2 ай бұрын

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

Hi, Where are all the ground connections please? My bike is not starting after a few weeks of not riding change the battery and the bendix and still not starting. Thanks

@TokyoOffroad

2 жыл бұрын

The main one which often goes bad is the battery ground strap connection to the subframe. Remove the strap connection and use a wire brush to clean the connector. Apply some dielectric grease (silicone grease works fine) will help keep the connection in good condition. The starter is grounded through the engine. The stator/regulator system has some ground connections to the frame located under the tank (remove the tank to inspect).

2018 TE150 - E start functions perfectly about 5% of the time. The other 95% of the time, the button does nothing and makes no sound. Battery is brand new. Have replaced the relay and starter button. Connections seem okay with no corrosion. Thoughts? Thanks for all the videos.

@TokyoOffroad

3 жыл бұрын

Using a multimeter see if you can trace back the source of the issue. Start measuring the voltage at the relay connections when you press the start button. If you always see voltage at the relay when you press the button multiple time, but it doesn't always click then the relay is probably bad. If however you sometimes don't see voltage at the relay it indicates that there is probably an intermittent contact issue with the starter switch, wiring, or connector. As you've already replaced the relay and starter switch the most likely causes are the connector by the headset, or a broken wire by the the headset.

Do the longer 2020 XRC bushings fit on a 2017?

@TokyoOffroad

3 жыл бұрын

No, it's not possible as far as I know. The standard length XRC bushings are very good and so long as they are held securely in the case bores and lubricated periodically should last the lifetime of the bike. Note that when the case bores are undamaged the XRC bushings will be a light press fit. However, the stock bushings tend to spin in the case bores, wearing the bore. If the wear is not that bad some Loctite retaining compound (either 638, or 648) can be used to secure the bushings in place.

Video is great but does not point out that the solenoid is powered by the battery and must be hooked up to the correct side of the relay. Well at least on my 2015te300.

Hi, i have problem with starter motor engagement, battery is fully charged, bike is ktm 250 tpi 2019 with only 20 hours. When cold starting this issue is very common especially in this cold days, i push starting button and starter motor is just spining, then i press rapidly few times button and then it grabs and start motor. When bike is warmed up then it is okey. Should i check bushings? I dont know but im not very happy with these bikes, they costs fortune and they have a lot of problems. In my first 20 hours on bike i had problems with cracked fuel filter, speedometer not working, front suspension oil leak, starter motor engagement.

@TokyoOffroad

3 жыл бұрын

Sorry to hear about the problems. When the weather is cold the battery voltage will be lower which results in the starter motor spinning slower. I doubt there is a problem with your bendix bushings after only 20H. More likely is that the bendix has become a little sticky internally. KTM applies grease to the flywheel in the factory and this is flung off very early. Some of the grease may have made it's way inside the bendix and if so will result in the sticky operation and often fail to engage in the flywheel, especially when cold. You could remove the bendix, clean it out internally (parts spray then blow out with air) and lube up with some dry lube, or light weight oil which doesn't become tacky. I experienced this with my 2017 when it was still fairly new and cleaning out the bendix made a big difference...

my starter spins the wrong direction, yes it does. any ideas?

@terryrich4285

6 ай бұрын

You have cross polarity somewhere

Hey man! Thanks for all good work! Have any clue why my electric start just spinn up with full force but wont start? 2020 ktm 250 tpi exc 12h.. ? Thanks

@TokyoOffroad

3 жыл бұрын

If your starter motor is spinning at full speed, but the engine doesn’t turn over it’s probably a problem with the bendix (has become sticky internally), or the bendix bushings are worn out causing misalignment of the bendix.

@predragkumanov8813

3 жыл бұрын

@@TokyoOffroad so that could be the problem on a almost new bike then? Sometime i starts, and then it stats easily! When i have the problem it wont start, if i put a gear in, and back to neutral it often starts.. Strange?!

@TokyoOffroad

3 жыл бұрын

@@predragkumanov8813 If it’s a new bike then the bushings won’t be worn out, but the bendix could be sticky. KTM put grease on the flywheel which is flung off almost straight away and creates a sticky bendix if it gets inside. You could try removing the bendix, clean it out internally using some parts spray and air, then lube it up inside using some dry lube, or light oil which doesn’t go tacky.

@predragkumanov8813

3 жыл бұрын

@@TokyoOffroad big thanks i will try that, have to see if im man enought to do that myself. Never checked in the starter motor area!

@predragkumanov8813

3 жыл бұрын

@@TokyoOffroad so i did check my bendix and itself was working smoothly, it did engage easily. But it was alot of sticky greese all around the area of the bushing and inside the bushing. And alot inside the cover that probably was comming from the fly wheel? I removed almost all sticky lub even inside the bushing... Is there ment to be alot of lub inside/around that area of the cover?

Do you keep a charger on your battery in cold weather??

@TokyoOffroad

3 жыл бұрын

I personally don’t use a battery tender permanently connected. I tend to ride my bikes regularly so the batteries normally stay charged just by riding them. But if I haven’t ridden a bike for a while I will charge the battery to ensure I don’t have any issues. If you have a lithium battery be sure to use a charger designed for lithium batteries.

@eddiekelley527

3 жыл бұрын

@@TokyoOffroad Okay thanks. I just had to replace a battery for my 2020 Husky TPI. Just wondering if it could have been avoided if used my lithium battery charger on a regular basis.

@TokyoOffroad

3 жыл бұрын

@@eddiekelley527 - Yes, lithium batteries do not like being deeply discharged, so if you're not riding regularly it's a good idea to either disconnect the battery, or use a tender designed for lithium batteries.

Great video, but why does KTM insist on 1992 Harley Davidson plugs and connectors?

@Jj12915

3 жыл бұрын

Because they know everyone is waiting in line with their wallets out anyway

@orange1666

3 жыл бұрын

Cheap crap made in Italy , all about saving money and maximising profit , those who take precious care seldom have issues , Inexperienced owners who don’t do maintenance or take care will have lots of problems and KTM takes their dollars !

@rocksolidhugo

3 жыл бұрын

@@orange1666 Italian electrics and Russian wine

If my bike had a starter problem my leg would be broken