Or do I need to open this up and see if there is a problem?

 

What does it do if you kick start it?

 

Never been able to kick start it 🫣
It starts if I use the electric start - just makes a racket, sometimes sounds as if it clinks a couple of times then catches, other times ‘spins’ other times fires straights up - but tends to start!

should there be any Visible playwith that first cog - I assume That goes through to the starter / sprague clutch?

 

Have you tried pulling the crank around to see if there is any play in it?
Might be easier to do with the fly wheel back on.

 

Flywheel is on at the mo - what do you mean ‘pulling crank’ to see if any play?
It’s not the way you describe it by the way - it’s my ‘learning on the job’ lack of knowledge 🤣

if I grab the first cog to the far left in picture above I can move it from side to side. Should I be able to? 🤷‍♂️

 

I think that cog in the first picture is the balancer shaft. I'm not sure how that should feel with the outer casing off as it might need the casing on to make it solid.

By "pull the crank" I mean to hold the flywheel on its side (or edge) and to push it towards the front of the bike (forwards), to the rear (backwards), upwards and downwards.
You're just trying to feel for any play on the main bearings, if there is any it should be quite obvious.

 

Also try the same with the second cog in the first picture, if you can get a good grip on it.

 

Second cog has zero play.
Like you say first one has but there are bearings in the outer case.

I’ll check the flywheel for movement 👍

 

Maybe I’m focusing on the wrong side and need to go back to the sprague clutch 🤷‍♂️

 

Ok - would over torquing the flywheel cause this issue.

like its is supposed to be 150nm

And it’s about 190nm!

(just discovered that my torque wrench only clicks in one direction and of course the bolt is a left thread so yeah I massively over torqued it!)

 

Ok - would over torquing the flywheel cause this issue.

like its is supposed to be 150nm

And it’s about 190nm!

(just discovered that my torque wrench only clicks in one direction and of course it’s a left thread nut.

Also sprag clutch I thought was some sort of one way bearing - is it supposed to easily spin in both directions (mine does with minimal effort from one finger!)

 

 

The sprag will turn easily, slowly.
As it speeds up, centrifugal force should make it crab the flywheel and turn the engine.
Number one cause of sprag failure is insufficient battery power to fully engage it.

 

Brand new battery and fully charged.
So it should spin in both directions by finger ?

 

Brand new battery and fully charged.
So it should spin in both directions by finger ?

if I turn it around and push it grips the edges and I can’t move it in one direction - or the other without force.

what about the Spring strength - if I push those teeth they rise - some don’t pop back down. Some easily move back in.

and why do the eBay ones sell at £30 and Ktm £96!

(PO says this is an eBay purchase!


also i could have sworn I removed this when doing the flywheel - but can’t for the life of me locate where it’s supposed to go now!
Any ideas?

 

I may have found the issue - ruddy cheap parts.
Opened it up and everything looked fine - but if I played with it even when oiled some of the little teeth were catching when I pushed them up and not returning.

Turns out the edge of some them was uneven with a lip and catching and it looks like the spring has already stretched and misshapen!

Just so happens a tight spring with same width is used in a 1969 mgb gt rear hub oil seal - and who doesn’t have a few of them lying around 🤷‍♂️🤣

Used some wet and dry to smooth out the edges of the where there are lips and the new spring is holding everything tight so 🤞

even if it only solves the problem short term I know I can order an OEM sprague to sort everything without it being a potential waste of money. (One on the left is the one removed with less than 100 miles on it!

 

Its surprising how rubbish non genuine parts are. I used a few non genuine gaskets when i put my one back together and most are leaking.

 

I keep hearing that from Ktm owners so far I’ve stuck to OEM ones. 👍 stupid expensive for what they are but if it stops a leak then I’ll take it on the chin.

Im about to pour oil in so fingers crossed todays issue is exactly that - poor quality pattern part 🤞

 

Nope - still the same.
Sounds like shit on start up!

 

Bit the bullet, and buy genuine KTM.

 

#totes
Just trying to work out what to start with - sprag clutch , sprag hub or the gear!

anywhere recommended with a discount/ good prices on OEM stuff?
I tend to use Trevor pope.

 

HI, Any luck with the repair - Currently have same problem on 510 EXC and again fitted Cheap Spragg clutch and it lasted literally 100miles - But now found the outer crank drive sprocket (cup) that fits over the bearing has a hairline crack in it (Which could have been there from before) - No choice for me than new parts.