Wild Dog Adventure Riding

Technical Section => Make / Model Specific Discussions => KTM LC4 400/610/640 & 690 => Topic started by: Doerengone on April 06, 2012, 02:41:18 pm

Title: KTM 640 Adv: Cheap R300.00 starter fix.
Post by: Doerengone on April 06, 2012, 02:41:18 pm

I have a 2007 KTM 640 Adv, with some 40,000km on the clock, and a sick starter.

When I pressed the starter button, the relay just  clicked, but would not turn over the motor. I checked the battery, recharged it, etc etc. Came to the conclusion that the starter needed new brushes. However, KTM only replace starters at R4,500. No brush kits are available from KTM. Eina.

So, after some googling, I got a brush kit from the local Honda dealer, at a cost of R300. Fitted same .......and my lovely burst back into life at the first push of the button.

Details: The starter kit is from a 1987 Honda CBR600, which is a perfect fit. (Get both the packet with the backing plate with one brush in, plus the second packet  with the second brush and the attached electrical feed bolt) Then fit the two parts to the starter. Part numbers on the two packets of parts are: 31206-MN4-008 for the backing plate, and 31201-KS5-901 for the single brush.

If further details of the fitment process is required, check on ADV Rider under thumpers, starter fix/replacement thread.

Cheers.

Title: Re: KTM 640 Adv: Cheap R300.00 starter fix.
Post by: buzzlightyear on April 06, 2012, 02:45:46 pm

Nice!

Title: Re: KTM 640 Adv: Cheap R300.00 starter fix.
Post by: AntonW on April 07, 2012, 10:08:04 pm

nice to know

thanks

Title: Re: KTM 640 Adv: Cheap R300.00 starter fix.
Post by: Lappies on April 10, 2012, 12:23:07 pm

Wow, good to know!

Thanks

Title: Re: KTM 640 Adv: Cheap R300.00 starter fix.
Post by: thysman on April 10, 2012, 12:53:03 pm

Thanks for sharing  :thumleft:

Title: Re: KTM 640 Adv: Cheap R300.00 starter fix.
Post by: sventer on May 28, 2012, 04:29:31 pm

Great I hope it works for my starter problem!

Title: Re: KTM 640 Adv: Cheap R300.00 starter fix.
Post by: reset1 on September 17, 2012, 09:07:03 pm

sweeet thx

Title: Re: KTM 640 Adv: Cheap R300.00 starter fix.
Post by: AntonW on March 05, 2014, 04:03:46 pm

I received a call from Superfoxi telling me i need new brushes on my 640. Thanks to me remembering reading this thread and the search button.

the parts were ex stock at Honda Cape Town for R 402.77

Title: Re: KTM 640 Adv: Cheap R300.00 starter fix.
Post by: igeorge on March 10, 2014, 02:35:49 pm

Thanks man!!!

Title: Re: KTM 640 Adv: Cheap R300.00 starter fix.
Post by: AntonW on March 11, 2014, 08:10:11 pm

Spoke to Superfoxi today and parts fitted perfectly.

Honda to the rescue   :biggrin:

Title: Re: KTM 640 Adv: Cheap R300.00 starter fix.
Post by: sventer on March 26, 2016, 10:32:52 am

Hi,

My 2007 model has the following starter problem:
When the bike is cold or hasn't been used in a while the electric starter shorts the electronics makes an electric sound but the dashboard lights go out and comes back on. The speedometer also gives a speed reading. But the engine won't turn. After I kick start the bike and the engine is warm after a few kilometers the electric starter works again.

Anyone with an explanation or fix for this issue. The problem makes it difficult to use the bike for normal day to day riding as I struggle to kickstart the bike without my motorcross boots.

Cheers

Title: Re: KTM 640 Adv: Cheap R300.00 starter fix.
Post by: Herklaas on March 26, 2016, 10:43:30 am

 :sip: Your brushes could be worn right down and arcing, causing the shock to the electronics. I thinks.

Title: Re: KTM 640 Adv: Cheap R300.00 starter fix.
Post by: Herklaas on March 26, 2016, 10:45:04 am

 :sip: I suppose I should say your starter motor brushes is worn down.

Title: Re: KTM 640 Adv: Cheap R300.00 starter fix.
Post by: superfoxi on March 26, 2016, 10:56:51 am

Quote from: sventer on March 26, 2016, 10:32:52 am

Hi,

My 2007 model has the following starter problem:
When the bike is cold or hasn't been used in a while the electric starter shorts the electronics makes an electric sound but the dashboard lights go out and comes back on. The speedometer also gives a speed reading. But the engine won't turn. After I kick start the bike and the engine is warm after a few kilometers the electric starter works again.

Anyone with an explanation or fix for this issue. The problem makes it difficult to use the bike for normal day to day riding as I struggle to kickstart the bike without my motorcross boots.

Cheers

Sounds more like a faarked battery to me...