Electric start it's finally here

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darrenrav

Joined May 2002

14 Posts | 1+

Manchester UK

Discussion Starter
• Aug 10, 2004

• #1

After over a year of waiting, my electric start kit is here. I've downloaded the workshop manuals from here (Thanks) and I'm about to fit it. I have a question before I start pulling my Berg apart what should the kit consist of, I ask because I have a box full of KTM parts which consist of the following:
1 x starter motor
3 x gears - 1x reduction gear 1x inner gear 1x outer gear
1 x clutch unit
1 x needle roller that looks like it fits into the outer gear for the inner gear
1x whole load of wiring
I'm not to worried (yet) about the wiring but should I have anymore needle rollers for the reduction gear?

thanks Darren

 

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44014

Joined May 2004

303 Posts | 2+

BRISBANE

• Aug 10, 2004

• #2

reduction gear des not run any bearings just runs in the case i would say that the bearings are just for the sprag


cheers doug

 

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darrenrav

Joined May 2002

14 Posts | 1+

Manchester UK

Discussion Starter
• Aug 10, 2004

• #3

Doug,

Thanks for the speedy responce, how easy or difficult is installing the e-start?

thanks again

Darren

 

4

44014

Joined May 2004

303 Posts | 2+

BRISBANE

• Aug 10, 2004

• #4

you will have to split the cases unfortunetly get some crc/wd40 onto your engine mounting bolt and the swing arm pivot shaft there a bitch to get out 8O have fun dude

cheers doug

 

Simon

Joined Jun 2001

1K Posts | 3+

Berkshire, England

• Aug 11, 2004

• #5

What year is it Darren?

Simon

 

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darrenrav

Joined May 2002

14 Posts | 1+

Manchester UK

Discussion Starter
• Aug 11, 2004

• #6

It's an 02 model 470- FC I think (it's the motorcross version that's been put on the road)

with ref to the e-start, looking at the pics on the workshop manual I only need to remove the clutch cover surely, however I will stand corrected though.


thanks again

Darren

 

Simon

Joined Jun 2001

1K Posts | 3+

Berkshire, England

• Aug 11, 2004

• #7

darrenrav said:

It's an 02 model 470- FC I think (it's the motorcross version that's been put on the road)

with ref to the e-start, looking at the pics on the workshop manual I only need to remove the clutch cover surely, however I will stand corrected though.


thanks again

Darren

Click to expand...

That's correct, it all sits behind the clutch cover although you will need to remove the clutch too. The needle rollers in the crank and clutch cases should already be in place for the gears to just slot in.

Cheers,
Simon

 

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darrenrav

Joined May 2002

14 Posts | 1+

Manchester UK

Discussion Starter
• Aug 11, 2004

• #8

Thanks Simon, don't suppose you can help with my side stand request could you?

 

Simon

Joined Jun 2001

1K Posts | 3+

Berkshire, England

• Aug 11, 2004

• #9

darrenrav said:

Thanks Simon, don't suppose you can help with my side stand request could you?

Click to expand...

Yes, I'll take a photo this afternoon - do you have a single mail size limit on your account (e.g. max message size of 2meg etc.) ? - just so I know whether to reduce the image or not.

Ta,
Simon

 

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darrenrav

Joined May 2002

14 Posts | 1+

Manchester UK

Discussion Starter
• Aug 12, 2004

• #10

it's too long

I attempted to fit the long awaited e-start kit tonight, and can across my first problem:

Is the new style starter motor longer by about 5mm than the older style motor, the motor mount thats been supplied doesn't fit.

Also why does the gear on the crank have two alignment dots

thanks guys

Darren

 

DOLLARS

Joined Jul 2002

84 Posts | 6+

manchester,england

• Aug 12, 2004

• #11

Darren sorry cant help with questions but i live in manchester and we go out most weekends on the moors above rochdale bog bashing give us a shout if your up for it.

 

Simon

Joined Jun 2001

1K Posts | 3+

Berkshire, England

• Aug 12, 2004

• #12

Re: it's too long

darrenrav said:

I attempted to fit the long awaited e-start kit tonight, and can across my first problem:

Is the new style starter motor longer by about 5mm than the older style motor, the motor mount thats been supplied doesn't fit.

Also why does the gear on the crank have two alignment dots

thanks guys

Darren

Click to expand...

Darren,

Double check with whoever supplied the kit to make sure you got the right bracket. The starter motors changed in 04 with a beefier one and you may have been supplied with a bracket for 01/02 bikes IYKWIM.

The 2 dots on the crank gear are alignment dots. The single dot on the counter shaft above should line up between those two dots when the engine is at tdc.

HTH
Simon

 

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darrenrav

Joined May 2002

14 Posts | 1+

Manchester UK

Discussion Starter
• Aug 12, 2004

• #13

Thanks Simon,

My E-start kit is not a kit as such more a collection of bits in KTM boxes and what look like parts taken from other bikes, the good news is that all the gears and motor are new the wiring looms, battery box and bracket are "used" which would explain why the motor didn't fit the bracket.

Thanks again for you help

Darren