2010 KTM 300 XCW-E Starting Problem

OTHG_HOGG · 05-20-2011, 11:54 PM

I have a 2010 KTM 300 with the "magic" button. Pretty much the whole reason I traded my 2006 CRF450-X in for this was less weight and electric start! I bought it last year, I don't race, or even had time to ride much this last year. My bike has a total of 14.8 hours on it and pretty much from the second day I had it out I noticed it didn't start anywhere as good as my 450-X. At first it was like it had a low battery feel, I replaced the battery. Shortly after it wouldn't start the bike at all, although the few times it would catch and roll the engine over adequately it wouldn't fire. Now it wont turn the engine over at all. Remember, this bike has less than 15 hours, which means the starter may have a total of actual 5 mins operation. I took it to the dealer, they took it apart to find the bushings for the reduction gear completely wore out. The dealer is saying as little as possible, like they are hiding the obvious, that being that this part of the bike is poorly engineered. I would like to know if anyone else is having or had a similar issue. If and what they did to fix it,and possibly a contact # to ask KTM directly how they are going to fix my $10,000 investment before I bad mouth this bike,the dealer and how poorly they stand behind their so called "best in the woods bike" all over the net. Would you buy a bike if you were told the starter is only going to last a week and only use it after it has been run for awhile,no cold starts allowed, and if you do have a problem that is a factory engineered flaw in design,your on your own the second you sign the papers?

bajadog · 05-22-2011, 06:49 PM

Hey Hogg,

I understand that feeling you are having, I had it with my
650R. Not to defend bad engineering if that is what it is, but
there are always some percent of plain old bad parts out there.

With all the outsourcing most manufacturers are doing now, it's
getting harder to hold tolerances and quality.

My Berg has your same engine I am told, and I have 60 hours on
the meter, and no starter issues.

Maybe just odds?

WoodsRiderParts · 05-23-2011, 08:51 PM

Have them replace it...I have heard of issues with that starter. The bike itself is great, but there are some issues there.

jsutton · 06-27-2011, 06:30 PM

Hi Hogg...I purchased a new 2011 KTM 300 XCW this last Saturday..by Sunday afternoon the starter was engaging maybe 40 percent of the time.
Seems to be getting worse today. The dealer was closed today but I plan to talk to them tomorrow..
Have you had any luck with yours..it is disappointing at the very least to have this problem persist in their bikes for over 7 years now..must be a difficult problem to remedy. John

compmoto · 06-29-2011, 08:20 AM

would a higher amp battery improve the problem ? Fresh, hot batteries sometimes help electrical issues... I put a Shorai battery in a Gasser 300e, with improved results. Claimed 2 year lifespan. Said to hold a charge for a year without maintenance ... much lighter,and more CA. Yes, we sell 'em, but these ARE good selling points, if they hold true. By all accounts, no issues yet...My 690SM had a decompression mechanism problem which was fixed by my now defunct dealer , under warranty. He replaced a battery, and starter unit before he,and KTM figured it out ...
I think, starters on these bikes, are more for "dead engine" starts in competition use. Not nessasarily constant "all-around" use... as long as there is a kickstarter lever. But that said, I don't know of any "streetbikes" that have this type of issue. Besides, of course, a manufacturer couldn't/shouldn't expect the customer to only use it for "competition" events ...what if you get in a "bad spot" , on a hill, or in a mudhole ? Or just too lazy, or because"I bought a bike w an electric start" why the heck doesn't it work ...all the time ?

jsutton · 07-02-2011, 01:27 PM

Well, I went to the dealer today..pretty much a waste of time...he took the housing apart, cleaned out all the white grease put there by the factory, spray oiled it and put it back together...still not engaging 100 percent of the time,
Tested the battery..13.1 volts..put a charger on it to boost the voltage..still not engaging all the time. Telling me its working properly when it spins without engaging even when he hits the button at times..
He says he's never seen this problem before..plans on calling service reps at KTM on Tuesday..How common is this problem on new bikes?

OTHG_HOGG · 07-13-2011, 11:20 AM

Ive actually been out of town past few weeks, just got in. I plan to check with the dealer to see if they received the new bushings. I have been riding it without the E-start motor and gears in place and am finding you really dont need the starter. This coming from a guy that bought this bike because of the e-start lol. It starts so ridiculously easy. I think Im going to remove all their piss poor engineering/selling feature and run it as a kicker, put a rekluse on it and should never have to worry bout stalling. I am starting to think that this idea of putting a starter on this bike did KTM more harm than good. I'll take the 9 pounds off...great bike even without the e-start. I'm still pissed at my dealer for not stepping up to help me out..after I bought my last 3 new bikes from them.and KTM for designing this cheap poorly engineered market driven add on that only lost customer confidence.

OTHG_HOGG · 07-13-2011, 11:28 AM

another thing..seems everytime someone else has a problem with their e-start , there is some little differences in how the problem shows itself...like the whole design is flawed in so many ways. It shows up as a slightly different characteristic each time. I'm thinking we are going to read about this failed attempt a lot more. All at the cost to us..thanks KTM

OTHG_HOGG · 08-13-2011, 06:05 PM

Hahaha...my point exactly compmoto..
In my case I dont think a higher amp battery would help..all the bike needed was 'some' grease on the starter gears to prevent the damage that has happened. The bushings wore out from lack of any grease and the gears ran in their bearing bosses on an angle causing some gear drag and damaged the teeth on the gears. Sux. I'm still thinking that this bike kicks so easy and starts everytime first kick I dont see paying more $$$ to fix their mistake.

OTHG_HOGG · 08-13-2011, 06:18 PM

Quote:

Originally Posted by jsutton

Well, I went to the dealer today..pretty much a waste of time...he took the housing apart, cleaned out all the white grease put there by the factory, spray oiled it and put it back together...still not engaging 100 percent of the time,
Tested the battery..13.1 volts..put a charger on it to boost the voltage..still not engaging all the time. Telling me its working properly when it spins without engaging even when he hits the button at times..
He says he's never seen this problem before..plans on calling service reps at KTM on Tuesday..How common is this problem on new bikes?

Just stopping in to see if you had your starter issues addressed.