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Enduro Electrical & Wiring Lighting, Ignition, Wiring, Plugs, etc.

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Old 01-19-2021, 12:28 AM
Demi Demi is offline
Join Date: Oct 2012
Posts: 42

That is the problem, good mechanics are a rare breed these days. Guess there is a difference between tech and mechanic?! Anyway, good thing these bikes are relatively simple, but can be frustrating for many. You're right though, just tossing parts blindly isn't the best solution. Annoying when the consumer has to figure out r&d or finish what isn't.

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Old 01-20-2021, 09:08 AM
mitinsky mitinsky is offline
Join Date: Oct 2020
Posts: 8

Originally Posted by farmerj View Post
Rieju has upgraded a number of parts in the starter system, and I suspect that starting problems are a thing of the past with the new bikes.
Let us know how it goes!
I doubt global changes ... The run is 20 hours and there have already been cases when the starter was idling on a hot motorcycle. It also did not start at +2 Celsius, but then I think the problem is in the battery.
Rieju MR300 Racing
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Old 01-26-2021, 12:55 AM
ECRider ECRider is offline
Join Date: Apr 2009
Location: Western Australia
Posts: 45

Here's a new one for electrically minded Gasser riders out there.
So I have upgraded my starter system by doing the wet mod & installing larger cables including a dedicated earth cable however I am still having intermittent start issues where the starter works & then goes totally lifeless.
I have installed new starter button & soldered its wires directly to the wires at the connector behind the headlight & have also replaced the starter solenoid.
When this was first installed it started great however during a ride it goes dead again.
I can get the starter working again by simply disconnecting the low amp cable connector from the bottom of starter solenoid & then reconnecting it.
I've cleaned the connectors before & used dielectric grease on it but doesn't seem to help.
Its sort of like resetting a computer by turning it off & doing a restart.
Any ideas?
GG GP300 18
KTM 350EXC 17

GG EC 450, GG EC 250 08, KTM 525 EXC 06, KTM 400 EXC 01, XR400 97, VTR1000 98, VFR750 95, Husaberg FE400 96, RMX250 91, Maico 490 84, IT250J 81, RM250C2 79, Bultaco Alpina 250 77 - All sold
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Old 01-26-2021, 08:06 PM
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gg3 gg3 is offline
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Join Date: Apr 2007
Location: BOP,New Zealand
Posts: 564

Originally Posted by gg3 View Post
My second cheap KTM copy starter arrived.Did the 180 degree rotation to change rotation to clockwise & tried it.
Still not turning over great but worked.Recap of process-
All positive & negative leads replaced with bigger cable & clean all contacts & earths.
Ran new earth to starter motor mount.
Replaced stator(was ok in hind sight).
Lithium 240cca battery fully charged 13.4v
New AS3 bendix cover & doubled the gaskets.
Welded bendix shaft then got a OEM new bendix (which came welded).
Checked the bevel gear parts 17 & 20 engagement & greased.Checked bevel gear bearings are smooth & whole assembly with pinion gear operate smoothly.
filed & cleaned up sharp edges on the flywheel/ring gear.
Spent countless hours with shims,washers,gaskets & gear marking grease to check & correct engagement of parts.I am fairly convinced the main problem is the pinion gear & bendix bind up when under load.
I am thinking there are new bikes with the pinion shaft & bendix shaft not running parallel and/or distance apart not correct.Other bikes as they get hours up the shaft housings are getting out of round or sloppy causing binding.Both are made worse by small cables not getting enough power to the starter & the constant binding & load is burning out the starters.
The last starter I had I ruined by constant testing.It still spins up fast but has lost torque.I'm sure the new one will give up as well after a while.I am going to try fitting a low friction bush into each end of the bendix shaft housings & then machine down the shaft ends to fit.
UPDATE- Bushes didn't work. Considered selling it as immensely pissed off, but still love riding it. Did the conversion to 24v & it starts supper fast cold or in gear. Will report back after a couple of rides. Hopefully it will not destroy the starter motor or wreck the pinion/bendix gears.
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Old 01-28-2021, 06:23 PM
fred99999au fred99999au is offline
Join Date: May 2018
Posts: 80

Ive been having issues with mine since new. Fitted a bearing to a new bendix cover and it made no difference. I fiddled around with it and made a thicker bendix cover gasket and added it to the original and it seems to work ok in the shed.

Havent had the time or inclination to go out and test it in the real world as yet.
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Old 01-29-2021, 05:08 AM
Demi Demi is offline
Join Date: Oct 2012
Posts: 42

I see some are doing the wet mod, approximately this enough to warrant a vent?
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Old 01-29-2021, 06:29 AM
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Gasser Nate Gasser Nate is offline
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Join Date: May 2010
Posts: 481

Originally Posted by Demi View Post
I see some are doing the wet mod, approximately this enough to warrant a vent?
Beta doesn?t run a vent at all, they only have about 25ml though. I run one cause it is easy enough to do. I have about 100ml in mine.
Back on a gassy! 2018 EC300! 🤘
Txt 280 07 to make me feel like a gumby again
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Old 01-29-2021, 06:33 AM
Demi Demi is offline
Join Date: Oct 2012
Posts: 42

Thanks Nate! Always appreciate your knowledge.
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Old 01-29-2021, 01:56 PM
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(F5) (F5) is offline
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Join Date: Jul 2006
Location: Wellington New Zealand
Posts: 1,664

We wet mod a mates 15, it blew some out so we added a vent and tube run to headstock.
'07 EC300
496 CPI Cheetah RZ/RGV hybrid
675 Street Triple R
RS125 framed MB100 racer
Stinger T125 Suzuki
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Old 01-30-2021, 01:24 PM
Demi Demi is offline
Join Date: Oct 2012
Posts: 42

Good info (F5), thanks. I fitted the AS3 cover yesterday, nice piece. I will probably do the wet mod if/when that Russian made kit ever gets sent/received.

I may have missed some of the photos in the various threads, but are there any good close up photos of the ground wires near the starter and otherwise? Going to add the extra wires in the 8awg format, maybe include fuses as well. Once the Russian kit comes in, will more than likely do a 24v conversion too.

Probably making alot of busy work though, when I got the bike from the seller, it started just fine in 40?F temps.

Edit- I see that my CDI is one that was supposed to be sent for a re-flash, what is this and how much of a change does this make? What's the indicator if it has been done? The original owner got it winter of 19.

Edit #2- would a CDI from say a 2012/13/etc fit and work for the 18+? I was on the fence about maybe an HPI or Ignitech down the line..

Last edited by Demi; 01-30-2021 at 02:46 PM.
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