KTM 520EXC Electric Start Issue Please Help

[Jacob-1919]

Hi Ktm enthusiast, iv'e  got a problem with my 2001 520exc i'm hoping to get some advice about.

 

So on every cold start the electric start begins to turn the engine for a moment then seems to lock up and spin real slowly as if there's too much compression or something. (even with a full charge) But a decent kick will get it started without any trouble almost all the time. That's the first problem.

 

The second issue is that even after its nice and hot the electric start will crank over the motor at a far greater rate but still wont fire. Just winds over quickly. Once again a good kick and it fires to life easily.

 

At first i assumed that this was fairly normal (at least the cold start issue) but now my brother has bought a 2003 525 Exc (almost identical motor) and it has no issues with electric starting; hot or cold, so there must be an issue somewhere.

 

Mine has a new battery, there is good spark and the clearance on the valves is fine, so any other suggestions would be much appreciated.

[sirthumpalot]

Check the starter torque limiter. There are some YouTube videos showing the issue on a similar motor.

[Jacob-1919]

Thanks for the info. I'm not sure that could be the problem as wouldn't the starter still turn over freely if the torque limiter was slipping?

[sirthumpalot]

May or may not be the problem, check this out to see if it matches your symptoms:

[dirteta]

I have read the stator can be at fault in this situation. The estart can draw too much not leaving enough to generate a good spark.

[Jacob-1919]

Yes i have heard that as well. Just by looking whilst cranking the motor with the plug out there seems to be fairly even spark between kicking and using the button.

What is exactly goes wrong with the stator to cause this issue?