klx450/kx500

[ylwgtr]

ok guys....Im posting for you sandblaster Id like to have a bit more for you guys but ive been busy at work,plus ive been waiting for the internals to show up,but its going to work....Im pretty sure you can work out whats going on here

[Twosmokerfan]

I'll take one please!

[sandblaster]

ok guys....Im posting for you sandblaster Id like to have a bit more for you guys but ive been busy at work,plus ive been waiting for the internals to show up,but its going to work....Im pretty sure you can work out whats going on here

YES!!!!! I LIKE IT!!!  

[dave916]

Freeride electric start, will it clear the exhaust/frame?

[ylwgtr]

its a 300 cover...It clears!!!....it was the first thing i checked.....your going to have to give me a little more credit than that dave! ....however i can swivel the cover to orientate the starter more vertical if i had any problems.....This setup will give me a full 12v DC charging system aswell.....When the internals turn up i will have more information for you guys on how this is going to work....I may be machining the side of the crankcase off (where the original cover bolts to) about 8mm or so....i may also need to relocate the clutch cable mount but i might be able to incorporate it into the adapter plate that im making.....I will also be running the KTM flywheel/generator/pulse pickup and a mappable CDI...something that i feel this engine will greatly benefit from.....Im not sure if the victa auto decomp will activate under cranking untill i get it turning off the starter however I have a few ideas to combat this.

One being the early victa decomps are servicable,so i may use one of those and try a stiffer spring in it or worse case scenario is ditch the victa and use a normally closed egr solenoid that gets energised by an aux out on the CDI brain under say 300rpm  

[ylwgtr]

but you have an interesting point dave.....i wonder if the freerides have a diffrent cover....maybe easier to adapt?I must check the part numbers....although the 300 one appears to be quite easy i must say

[ylwgtr]

Another thing i will add is these parts are not cheap!!!Its prob going to cost me a grand or so....but hey....all in the name of R&D huh?

[kxpegger]

Before you spend a bunch of money you may want to do a search at Thumpertalk or KTMTalk. The KTM 300 starters are a known problem and most often do not have enough cranking power to start a 300 let alone a 500. There are hundreds of posts of slow cranking or no cranking on the 300's. KTM has known about this for years and years but for some reason has failed to upgrade the 300 starting system. The KTM 4 stroke starters seem to work fine. I'm not a KTM basher; I own two of them.

[ylwgtr]

hi kxpegger....Im running an auto decomp that kickstarts like a minibike....im also using the updated 410w starter off the new model....Also running a bit of oil in the case seems to help a bit as they are only pissy bushes on the bendix drive....infact i think because of my decomp i reckon my starter will be having an easy time comared to the undecomped 300 its designed to work with....no turning back....ive already paid for the parts....Im prepared to take one for the team

[kxpegger]

10-4! I think the decomp alone should take care of it. Looking forward to seeing you pull this off!

[sandblaster]

Me too.
Thinking about those times being stuck on the side of a hill, engine dead, and no way to turn around.... Wouldn't it be nice to touch a button and go?

[ylwgtr]

not really bike related but another reason why i havent had much time for this project....I work in a never put your eggs in one basket job....this is a run of billet quad disc floor polishing machines with a planatry gearbox

[alward25]

They make a upgraded starter that is pretty cheap or buy the fix it kit for the KTM

[jBernard]

Nice machining!
are you in the states? Maybe some of us can send you work if thats an option? maybe get a forum discount? 

[ylwgtr]

Hi jbernard nah mate in Australia!!