New starter torque limiter

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by Sadlsor, Aug 18, 2007.

  1. biggus

    biggus Been here awhile

    Joined:
    Mar 15, 2007
    Oddometer:
    379
    Location:
    Ubon Ratchathani, Thailand
    #41
  2. kingrj

    kingrj Been here awhile

    Joined:
    Aug 14, 2005
    Oddometer:
    476
    Location:
    Hattiesburg, Mississippi

    When I did my conversion I looked at the generator covers and thought "hell why did they send a new cover? These things look just alike!". So smart me re-used the old cover and guess what? It bound up the works and locked up the motor until I put the new cover on. I have not done a detailed measurement to see just what the differences are but I can tell you that there is a good reason to use the new case. :deal
    #42
  3. Katoom72

    Katoom72 Been here awhile

    Joined:
    Jun 3, 2012
    Oddometer:
    946
    Location:
    Belgium
    Some parts are wider, think im gonna do the swap today so il make some measurements on the new parts.
    #43
  4. DrKayak

    DrKayak Retro Rider

    Joined:
    Mar 2, 2010
    Oddometer:
    815
    Location:
    Shingle Springs CA
    I did mine last week. So cool that the 950 now starts like any other motorcycle. none of that clanking if you crack the throttle the least bit. So much easier to start when you can whack the throttle slightly as you start it. Should have replace it years ago.

    Pretty easy swap.

    I think the new method of limiting torque is like a friction clutch built into the new case. The old method was those rounded gear slipping that were replaced.

    The kit is less $$ at CheepCycleParts.com than KTMtwins.
    #44
  5. howl

    howl 990 Adventure

    Joined:
    Mar 28, 2006
    Oddometer:
    98
    Location:
    West Sussex Blighty
    There was a recall in the UK,I had my 06 990 one replaced free of charge but that was back in 06/07.
    #45
  6. biggus

    biggus Been here awhile

    Joined:
    Mar 15, 2007
    Oddometer:
    379
    Location:
    Ubon Ratchathani, Thailand
    Any way to get KTM to pay for the kit? 06 950S with only 10k miles?
    #46
  7. Sadlsor

    Sadlsor Been here awhile

    Joined:
    Oct 16, 2003
    Oddometer:
    691
    Location:
    Magic City in the Heart of Dixie
    My 05.5 -S model began this nonsense shortly after I bought it used.
    Was so loud and obnoxious, I was embarrassed to start it when anyone was around!
    Thankfully it's an easy fix. At this late date, I think it's at the dealer's discretion whether the kit is no charge to the customer.
    #47
  8. Katoom72

    Katoom72 Been here awhile

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    Jun 3, 2012
    Oddometer:
    946
    Location:
    Belgium
    It depends on the dealer, there is no harm in asking or writing to KTM themselfs about it.
    #48
  9. biggus

    biggus Been here awhile

    Joined:
    Mar 15, 2007
    Oddometer:
    379
    Location:
    Ubon Ratchathani, Thailand
    I bought the bike from Cycle Shed in Indiana over the phone in June of 07 and shipped to Pennsylvania, now bike is with me is Thailand. I e-mailed them within the last year about this but never received a reply.

    The KTM Dealer here in Bangkok has the kit in stock but it is almost $400!
    #49
  10. jeffz

    jeffz Adventurer

    Joined:
    Apr 3, 2007
    Oddometer:
    25
    Location:
    Mesa, AZ
    Thanks Sadlsor for your pics. Very helpful.
    I searched for the kit, and ended up ordering from ktmpartspitstop. They had the best prices.
    My 06 950SM has had the clack since new. When I complained, they offered to install the kit if I paid for the part. I decided to soldier on. Almost 7 years and 23K miles later, it really needs to be done now. The kit is only about $20 more than what they quoted me in 07.
    Thanks to all for their contributions here.
    #50
  11. EastSideSM

    EastSideSM Isn't that dangerous?

    Joined:
    Mar 30, 2008
    Oddometer:
    1,491
    Location:
    Providence, RI
    Don't wait. Mine quit around that mileage. I got stranded. I ordered the kit and it was an easy install. Don't cut your fingers on the metal gasket when you try and line it up, that thing is like a razor blade.
    #51