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Old 11-29-2013, 07:45 AM   #1121
Beastly Adventurer
Joined: Apr 2007
Location: Reno
Oddometer: 1,425
These starters are a little fussy.

I always start with the battery and connections. Problems there will make you think it is in the bendix or starter.

Second is cleaning and lubing the starter drive gears. I seal the bottom vent and run a new vent up to the air box--much cleaner. Some put oil in the stator case. I have tried this but don't recommend it.

Other problems can occur with the bushings for the bendix, intermediate/crownwheel gear, bendix failures.

Finally there are starter failures. The pre 2013 starters are undersized. Brush and armature failures are common. I have had mixed success rebuilding. The 2013 starters are worth the extra $.

Slavens Racing carries all the parts. KTMTalk has lots to read on the subject.

KTMs--300, 518, 990
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