Starter will not engage...

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by Weekend Hack, Jun 14, 2011.

  1. Weekend Hack

    Weekend Hack Adventurer

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    So... My 04 KTM 950 Adventure wont start...

    Here are the symptoms and what I have done so far...

    Try to go for a ride Friday, bike won't start. When i hit the start button you can hear the starter spin, but not engage the engine as to start it. I figure maybe the battery is flat, so I try jumping it with my pickup (engine off), no luck. Then I pull it out and see its three years old, I figure its almost time anyway so I get a new one in the morning. Saturday I install the new battery and same thing stater spinning and not turning over. Damn it... Tip the bike on its side pull the tank and the take off the ignition rotor cover. Then I hit the starter button and can see the starter gear spin so I figure the freewheel clutch is shot, call the dealer and order parts. They got here today and I installed them... (by the way don't waste your cash with the 40$ KTM tools just get the 14$ gear puller from NAPA) get her all back together and guess what same f*%king thing... stater is spinning but not engaging.

    Anybody have any ideas where to go next???
    #1
  2. cpmodem

    cpmodem Orange Caveman

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    Make sure the rotor isn't spinning on the crankshaft. The early ones weren't keyed to the shaft and could spin. Especially if the "lapping" TB wasn't done.
    #2
  3. Weekend Hack

    Weekend Hack Adventurer

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    Thanks for the help...

    I looked at that as a problem but the rotor was well secured. So the problem was the starter was spinning backwards! There is a small o-ring that holds the positive post off the case of the starter. I assume the pressure from the positive starter wire squeezed the o-ring until the positive side touched the case making it run in reverse. Trip to the hardware store and .29 cent o-ring and it started like a champ.

    what a F-in nightmare...
    #3
  4. Qwik

    Qwik Adrenaline Addict

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    Wow. Thats a First for that one.
    #4
  5. cpmodem

    cpmodem Orange Caveman

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    Amazing the positive didn't short to ground. No fuse on that circuit. Would have been quite a lot of smoke.
    #5
  6. gefr

    gefr Life is a trip

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    This is really strange. Welldone.
    #6
  7. Aquanout

    Aquanout Hooliganantic

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    No kidding, on a scale of 1-10 on the weird-shit-o-meter thats at least an eleven.
    #7
  8. wayer

    wayer n00b

    Joined:
    Aug 28, 2003
    Oddometer:
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    Location:
    Hood River, OR
    My 2004 Adventure has the same problem. New fully charged battery or jump start makes no difference - starter spins, but the starter gears never engage.


    Where is the o-ring, that allowed the positive post to ground out to the case? Inside the starter, or outside?

    I've got two posts on the rear (bike's right) side of the starter. Neither has an o-ring. Disconnecting the rearmost (ground?) made no difference. Disconnecting the forward post cut off all electricity - turning on the key = no lights, no cranking, no nothing.

    Thoughts?
    #8
  9. Head2Wind

    Head2Wind MotorcycleMayhem

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    1 of 2 things:

    1. starter sprag failed (one way clutch)
    2. flywheel has come loose from crankshaft

    the "early" engines do not have a torque limiting function to the starter system, the gear system that connects the starter motor to the sprag is solid, no clacky clacky.


    Given the nature of the starter and how its configured, I cannot understand how the starter would rotate in the opposite direction if the terminal where the cable attaches becomes electrically connected with the case of the starter, and when normally mounted to the engine effectively connected to the negative side of the battery..... I call BS.
    #9
  10. YOGOI

    YOGOI Prick

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    Mine's a little different, When I push the start button nothing happens.
    I turn the key on and the dash lights up, the fuel pump primes when I flick the red "on" button, but the start button does nothing.

    Battery is good.
    I plugged in another ignition, no change.
    I plugged in another start-stop switch, no change
    I plugged in another starter relay, no change
    I plugged in another digital box, no change

    Any ideas on where to go next???
    #10
  11. Head2Wind

    Head2Wind MotorcycleMayhem

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    Neutral switch, clutch switch, verify the safety relays are functioning.

    Sent from ADVmachines.com via Tapatalk
    #11
  12. YOGOI

    YOGOI Prick

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    The bike is in neutral, and the neutral light is on on the dash, so that verify's that the relays are working, right?
    The kick stand switch has been gone for years, but, the bike is in neutral so that doesn't matter any whey, right?
    #12
  13. Head2Wind

    Head2Wind MotorcycleMayhem

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    will the starter motor run if you jumper across the two posts on the solenoid? have you jumpered to the "start" post on the solenoid to see if you can get the solenoid to energize? If the solenoid will energize by manually jumpering but the starter motor will not turn, while maintaining the solenoid in a energized state is battery voltage present at the starter motor post? If present, then the brushes are stuck or there is a internal fault in the starter motor. If the solenoid will not manually energize from a jumper wire, then the solenoid is faulty.

    I would have to review the wiring diagrams and the lock out logic to see if the side stand circuit either open or closed would cause the "start" circuilt to be isolated from the solenoid effectively not allowing the starter to operate.
    #13
  14. YOGOI

    YOGOI Prick

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    I'm gonna be able to dig into this today. I'll get back to ya with the findings, or more questions. :D

    Thanks for the help Head2Wind
    #14
  15. YOGOI

    YOGOI Prick

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    Found it.
    The wire that connects/communicates from the solenoid behind the light to the starter relay was broke. One of the wires has a separate connector that the wire had pulled out of.

    Also while I was at it. I found a wire that was broke in the ignition too. It was still make'n contact, but I could wiggle the wires around an make em short out.

    Thanks again for the reply's.
    #15