Question about 2003 KTM 640 LC4 Adventure

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Starter grinding As I engage the starter the motor will turn over but when the compression stroke kits the starter makes an awful grinding sound. I'looked in the manuals and see that it has a starter gear an would like to know if this item can be replaced without special pullers or having to split the cases.

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You must take off the right hand engine cover and after unscrewing CLOCKWISE the main bolt that holds the flywheel you need a special KTM puller to pull out the stator rotor (flywheel).Behind that there is a group of parts that you should replace.The large sprocket, the clutch system that the large sprocket is into (special formed balls in a spring) and the hub that is screwed behind the flywheel.Use OEM parts (even for the 5mm allen screws if they need to be renewed).Use 18Nm for those allen screws adding locking nut adhesive on their threads (Locktite).
Work backwords to reinstall it and the flywheel's main bolt uses 120Nm of torque to tight it up on the crankshaft COUNTERCLOCKWISE.Use new gasket for the engine case and 12Nm for the bolts.

Posted on Jun 03, 2009


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My mariner 60hp 2 stroke motor is playing up. When I turn the key over it makes a horrible high pitch grinding noise and won't start. The starter motor is engaging with the fly wheel but slipping on...

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sounds like,yes, Might try pulling the spark plugs and try it then,
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I just replaced the starter. When trying to start it I heard a grind and whine like it is not turning anything????Is my motor shot?

Please make it sure you are assembled it right.
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1 Answer

Changed the plugs wires and cap and rotor...think I might have screwed the firing order misfire just wont turn over.

the wires to the plugs should not keep the motor from cranking over. If the battery is fully charged the ignition switch should engage the starter. If you think the firing order is wrong you need to determine 1 where is top dead center (the position the motor is in when #1 cylinder is at the top of the compression stroke). 2 what direction does the rotor turn 3 what is the firing order One way to make it easy to rotate the motor is to remove the spark plugs. no compression means no resistance to the starter so the motor should turn over with the key in the start position. If it won't crank over with the plugs out then something is wrong with the starter, battery, starter relay, or ignition switch. I always start with the basics. the battery should have at least 12.5 volts. if it does check the battery terminals. even if the starter is weak you should hear a click when the key is turned to the start position. Once you get the starter to turn over the motor you can tell when the number one cylinder is at top dead center by putting a finger over the spark hole as you crank over. You will feel the compression as the cylinder comes up on the compression stroke. I have used a large socket to slowly turn the motor over and when you are near top dead center you should be able to see the degrees of advance on the timing mark. Set the motor at top dead center then see where the rotor lines up with the wires on the distributor cap. that is where number one cylinder should fire. You then follow around in the direction that the rotor turns and the wires will corispond with the firing order. I always make a mark on the number one spot on the cap with a felt pen. That way you have a fixed reference point. Take care to verify that all the wires are to the proper plugs before trying to start. Take extra care at this point and make sure your firing order and rotor rotation are correct. I would triple check this. The firing order and rotor direction are usually somewhere on the autozone repair web site

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1 Answer

Starter motor can't turn engine through compression stroke

valves are out of adjustment. reset them and it will do fine.

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if the starter is making grinding sound it not! however it could be loos and needs to be bolted up tight or there may be a bad power joint to the starter,, check for this also check all the earth leads off the engine to the battery, if its still grinding then its likely to be a dud starter you fitted,, the solenoid is not fully engaging the starter bog in the fly wheel teeth and it stopping short and then it spins up this is whats making the grinding noise, it can also make a right mess of your fly wheel ring gear,, so dont leave it to long to get it sorted out,

Mar 02, 2010 | 1999 Chevrolet Silverado 1500

1 Answer

My 1993 dodge shadow will not start, it will turn

Does it sound like a screeching or grinding sound? If so - it could be the starter is going out - there is a part called the bendix spring that is probably not engaging completely and it will cause the teeth of the starter to not fully engage the flywheel - which makes an awful sound.

Hope this helps and good luck!


Sep 18, 2009 | 1993 Dodge Shadow

1 Answer

High pitch noise when turn key to start / engine not turning over

Check your battery first. Cold weather does horrible things to car batteries... if it's more of a grinding sound I would say that your starter gear is bad. I believe they call it a ring gear? I had a similar problem with a kushman scooter that I use to deliver snowcones through the neighborhoods. It has teeth that need to engage and if those teeth have been grinded down it will have a hard time engaging....

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