Jamin
posted this on September 02, 2010 10:23
Examination of electric starter operation and specifically returned Bendix revealed that approx. 80% of the parts were fully functional.These examinations also revealed that poor starting performance is often caused by inadequate ground connection of the electric starter motor. While replacing the part with a new electric starter motor eliminates the problem, this is usually because the ground connection is simply reconnected. In case of starting problems, we recommend checking that the ground connection of the electric starter motor is properly connected before replacing the part. It is then advisable to re-cut the M6 threads indicated by the red arrows used to fasten the ignition cover in the engine case.

A further step to improve functionality of the electric starter motor is to carefully adjust the play between the crown wheel and the starter motor gearing. This can greatly reduce the frictional loss between the two components.
This procedure is described in the repair manual KTM 250/300 Item Code 3206088.
Excerpt from repair manual KTM 250/300 Art. No. 3206088.

Comments
Is it your recommendation to go with a wet system as many have done? I have used Red Line synthetic gear oil for a couple years now. I just can't seem to get much more than about 1 seasons riding in before my brushes wear out. Do you offer a brush kit for this starter?
What do you mean by 'wet system'?
This is the latest Brush Set:
the newly available bushing for the side cover/case/bendix shaft is 55140030100.
The bevel gear, or intermediate shaft coupling as KTM call it, also uses this bushing, and they can easily drop out when reassembling the case if you’re not careful. There are 4 in total.
I understand that you can get the shaft bushing & seal. Google "KTM starter parts" and check Rick. He may have them.
select a year and go from there…. it seems a full rebuild kit including the bearing & seal can be had.