Question about 2000 KTM 640 LC4

3 Answers

I still have problem starting My 2001 KTM LC4 supermoto.When I push starter button the engine tries to turn but starter disengages with a ratcheting sound. It did start once but after stoppiong it would not restart. I have been told to check starter freewheel but the DVD manual I have is not very clear on this. I have had the starter motor checked and they fitted new brushes so the problem seems to be in the freewheel. I cannot kick start it either.Compression is 140psi I have tried a few different batteries incl Jump start from car battery. Any other suggestions please

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  • pateli Nov 14, 2010

    See previous I have new fuel in tank I tried Starting Fluid No Good.The starter seems to disengage and ratchets without turning the engine.What do I look for igf I get at freewheel if this is the problem or what else can it be.

  • pateli Nov 20, 2010

    I have looked at the visual gearing and its ok I appreciate any Suggestions but has anyone stripped and examined starter free wheel as that is where I think the Problem lies

  • pateli Nov 22, 2010

    One other thing If I hold the Decompressor in the engine turns ok. Only under compression does the Fault appear. There are not may places in Dublin who will look at Motorcycle Starters.

  • pateli Nov 22, 2010

    Got some info about Freewheel on a website ADRider any help appreciated. Told today that my job is gone in 2 weeks. So will have time to investigate.

  • pateli Nov 23, 2010

    Thanks for takeing the trouble it is appreciated. I will start pulling it down next week. The guy on ADVrider has a series of photos showing freewheel dismantled. His problem was caused by a weak spring in freewheel which would not keep rollers engaged he says you cannot buy spring seperately but must buy complete freewheel but you can get over it buy getting an SKF oil seal p/n 19993 and removing spring which is correct size it done job for him.

    mally

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Hi, even though you had brushes put in the starter, did they take a look at the starter teeth for broken or missing one's? Well, anyway, I am sure they looked it over. The only other thing it could be is the flywheel/freewheel. When you say that the starter disengages with a ratcheting sound, makes me think that the starter is intermitent, and you need to have it bench tested like they do on auto's. They take a 2x4 piece of wood and that starter should dig right into a piece of 2x4 with no problem. It may just have weak windings. It shouldn't take you long to remove the starter. Take it somewhere else this time, and tell them what was done to it, but you still want it bench tested under a load. This is very important. Keep me posted on this. This is the step I would take. Then you will know for sure its not the starter. I believe it is.
Sincerely,
Shastalaker7

Posted on Nov 20, 2010

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  • Robert Horton
    Robert Horton Nov 22, 2010

    Let me check it to this a little further for you. I work today, but I will see what I can do to find out more information so we can solve this problem.
    Shastalaker7

  • Robert Horton
    Robert Horton Nov 22, 2010

    I talked to a man that is very much into these kinds of bikes and told him the problem you were having. I didn't even get all the way through the explanation when he said the problem was in the starter freewheel. Starter is ok. He didn't go to any detail on how to check this, but has seen this many times before on this make of off road bike. He suggested you tie it down in a pick-up truck, and take it to Hayward, or East to Livermore to a bike shop, and just have them show you how to get to this and tell you where you need to start. He did say that most shops are very happy to give a man pointers free of charge if you are willing to take your bike to them, and stay off the phone. He knows his stuff.
    Sincerely, Shastalaker7

  • Robert Horton
    Robert Horton Nov 22, 2010

    PS, this is a 2001 KTM, and he said that he has seen this problem several times on this on/off road bike. Its a great bike, but this has been a problem when the bike ages some. I wish you the best on this.
    Sincerely,
    Shastalaker7

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Remove the starter and use a flashlight to see the flywheel through the starters mounting hole opening. Turn the flywheel by hand using the kick starter lever. You can see if the teeth are all there this way

Posted on Nov 14, 2010

  • frank thomas wilson
    frank thomas wilson Nov 20, 2010

    If the starter was proffessionally tested the fly wheel is the problem

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Hello. I suspect that the actual cause of your troubles is old fuel. Read on. Whilst your bike was not operating for 3 months there has been no activity for the fuel... so, the fuel grows something like a moss or fungi in the tank... this is in the form of clogs, which is usually white for unleaded fuels.

So to make the engine to turnover again to start. All you need to do is, empty the fuel from the tank (Professionally or DIY) and fill it back up again with NEW FUEL.



Also get a can of starter fluid. IF the bike won't start with the new fuel, spray some starter fluid into the air intake and then crank it over. Keep it running with starter fluid if necessary for up to 5 minutes.


So when you leave your bike for an extended period of time (over 5 days) turn on the engine every 2nd day to clear out any white clogs, for only about 2 minutes.

And turn OFF the fuel switcher to prevent any fuel flow to the engine, which creates the white clogs.

Joe

Posted on Nov 14, 2010

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