Hi Sky,hate to bring up the 2018 shit starter thread again but I am also stumped & frustrated.Will share my experience & it may help.
Started worked ok when warm until about 80hrs then became hit & miss.Read the threads &
Fitted AS3 bendix cover.
Dis-assembled bendix & lightened the spring.
Heavier Pos. cables from battery to solenoid & solenoid to starter.
New Neg. cable from battery to starter & another battery to frame.
New LiFe 210cca battery.
Started much better & consistent when warmed up.Was happy with it.
At about 120hrs it became inconsistent.Turned over slow like it was under heavy load & not enough power.Put in a new LiFe 210cca battery,welded the bendix to bendix shaft,pinion(part 16) rotates freely but I couldn't get it out to reweld the shaft.Looks ok though.No difference so got a new KTM 410w starter,reversed polarity & installed.Marginally better & really pissed off with it now.Occasionally starts but sounds like it is really labouring.
With plug removed I can hold the button & it spins fast & smooth.
Tested solenoid & it clicks on/off but the battery tests at 13.8v & reads 8.2v at the starter when trying to start.Doesn't sound right? Comments please.
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