on the 2011 250 XCW parts diagram its in the ignition system schematic, item # 19. It's called a collar bushing P/N# 55140030100 and you need 4 of them total. They may have changed the part number in subsequent years but they're probably still listed in the ignition system schematic.
I used this type of reverse snapring plier. When you squeeze the handles together, the tips press outward. I put the tips inside the collar and squeezed the handles together. The tips pressed against the inside of the collar and I was able to pull the collar out. www.amazon.com/Lisle-49200-Heavy-Duty-Plier/dp/B0009OR8ZM/ref=sr_1_1/177-0477109-5003718?ie=UTF8&qid=1400193800&sr=8-1&keywords=heavy+duty+snap+ring+pliers
Hi Mike, I believe I have a problem with the brushes on my 2012 Husaberg TE 250. When I push the starter button, all I can hear is a short knock of the stator, close to the battery, on the left side of the bike. I thought at first it would be just a flat battery. There is no noise of the starter motor rotating at all. The battery is fine with 13+ volts. Any hints on this? I'll be going through the process of checking everything and hoping for just replacing the brushes. Still, is it possible to make a video on how to diagnose starter motor problems? Either using a multimeter, or maybe it is just playing it by ear. I think the DIY community would very much appreciate! Thank you a lot for this video!
That's the starter relay you're hearing. Mine would do that occasionally when it was cold, then after riding the bike for a couple of minutes the engine would warm up and the starter would work. Diagnosing it is kind of playing it by ear. I showed all of the problems I think you might encounter with the starter setup. If you go through the steps in the video and do all the repairs/mods you'll be happy. Mine is still going strong...hot, cold...doesn't matter. Very little freewheeling.
Hi Mike, Many thanks for the reply. Washed the bike last night and greased her all up so I'll be starting the repairs today, I expect. Best regards, Tiago
mx mike Hi Mike, Just got to track back this video of yours. It has got to be one of the best - if not the best - videos out there about KTM starter problems and ways to solve them/repair/maintain them. Combined with Jeff Slavens videos one's got a great team to stay in to! I got to sort out this problem I had about 4 months ago. The brushes where absolutely worn out. One of them didn't even had the graphite bit already. So I was able to clean it, replaced the bearing seal and greased up the bearing. The brushes were also replaced at a common electric motors repair shop as KTM didn't had this in stock. (I mean, if they know that this is a problem and it is a consumable thing, wouldn't you expect for a major KTM shop to have this in stock?...) So, everything got in place and ran whel untill last weekend. It's the brushes again. This time, I even got to face down the copper so it would be flat again as a deeper recess was in from the wear. Done everything right. I just hope I didn't get to little copper now... I'm now looking for brushes so I can replace them myself now. There are plenty of videos out here in TH-cam on how to do that as well to teach and inspire other ones. This time I might also open that housing and clean, grease everyting and also do again the wet modification as it was done from a previous owner. I hope to get some good news soon. Regards, great rides!
You can get a complete rebuild kit at ricksmotorsportelectrics.com/ktm-rebuild-kit.php for $75 US. It includes a new armature, so no starter troubleshooting required. The clicking sound beside the airfilter is the starter relay being activated when you push the starter button. Before you tear back into the bike, kickstart it and ride it for ~5-10 miles. Oftentimes, the starter won't work when the bike is cold and hasn't been ridden for a while. As the bike warms up, the starter works better and by the end of 5 miles or so, it will usually work great. Some people disconnect the battery negative wire between rides to keep the battery fully charged.
Great video, the alternative is a lithium battery, i just chucked in a 140cca lithium SSB same size but battery has more power
Great vid. After watching the Slavens vids this one ties in all of the issues and fixes. Great job and thanks.
Top video. I got a lot of information out of this, thank you!
on the 2011 250 XCW parts diagram its in the ignition system schematic, item # 19. It's called a collar bushing P/N# 55140030100 and you need 4 of them total. They may have changed the part number in subsequent years but they're probably still listed in the ignition system schematic.
Where did you find the collars? I'm having trouble figuring out where they are on the oem pictures.
Hey mike. Great video! One question. Doesn’t the battery get charged while riding the bike?
I know your comments old, but yes the battery gets charged while riding.
Mike how did you get the teflon collars out.
I used this type of reverse snapring plier. When you squeeze the handles together, the tips press outward. I put the tips inside the collar and squeezed the handles together. The tips pressed against the inside of the collar and I was able to pull the collar out.
www.amazon.com/Lisle-49200-Heavy-Duty-Plier/dp/B0009OR8ZM/ref=sr_1_1/177-0477109-5003718?ie=UTF8&qid=1400193800&sr=8-1&keywords=heavy+duty+snap+ring+pliers
mx mike Thanks, I didn't get to read your reply before I got the collars out but I ended up caving in the sides and pulling them out with pliers.
Hi Mike,
I believe I have a problem with the brushes on my 2012 Husaberg TE 250. When I push the starter button, all I can hear is a short knock of the stator, close to the battery, on the left side of the bike. I thought at first it would be just a flat battery. There is no noise of the starter motor rotating at all. The battery is fine with 13+ volts. Any hints on this?
I'll be going through the process of checking everything and hoping for just replacing the brushes.
Still, is it possible to make a video on how to diagnose starter motor problems? Either using a multimeter, or maybe it is just playing it by ear. I think the DIY community would very much appreciate!
Thank you a lot for this video!
That's the starter relay you're hearing. Mine would do that occasionally when it was cold, then after riding the bike for a couple of minutes the engine would warm up and the starter would work. Diagnosing it is kind of playing it by ear. I showed all of the problems I think you might encounter with the starter setup. If you go through the steps in the video and do all the repairs/mods you'll be happy. Mine is still going strong...hot, cold...doesn't matter. Very little freewheeling.
Hi Mike,
Many thanks for the reply. Washed the bike last night and greased her all up so I'll be starting the repairs today, I expect.
Best regards,
Tiago
mx mike Hi Mike,
Just got to track back this video of yours. It has got to be one of the best - if not the best - videos out there about KTM starter problems and ways to solve them/repair/maintain them. Combined with Jeff Slavens videos one's got a great team to stay in to!
I got to sort out this problem I had about 4 months ago. The brushes where absolutely worn out. One of them didn't even had the graphite bit already.
So I was able to clean it, replaced the bearing seal and greased up the bearing. The brushes were also replaced at a common electric motors repair shop as KTM didn't had this in stock. (I mean, if they know that this is a problem and it is a consumable thing, wouldn't you expect for a major KTM shop to have this in stock?...)
So, everything got in place and ran whel untill last weekend. It's the brushes again.
This time, I even got to face down the copper so it would be flat again as a deeper recess was in from the wear. Done everything right. I just hope I didn't get to little copper now...
I'm now looking for brushes so I can replace them myself now. There are plenty of videos out here in TH-cam on how to do that as well to teach and inspire other ones.
This time I might also open that housing and clean, grease everyting and also do again the wet modification as it was done from a previous owner.
I hope to get some good news soon.
Regards, great rides!
You can get a complete rebuild kit at ricksmotorsportelectrics.com/ktm-rebuild-kit.php for $75 US. It includes a new armature, so no starter troubleshooting required. The clicking sound beside the airfilter is the starter relay being activated when you push the starter button. Before you tear back into the bike, kickstart it and ride it for ~5-10 miles. Oftentimes, the starter won't work when the bike is cold and hasn't been ridden for a while. As the bike warms up, the starter works better and by the end of 5 miles or so, it will usually work great. Some people disconnect the battery negative wire between rides to keep the battery fully charged.
WD40!!!!!!!!!!