starting problems.

Right, starting problems, here we go...

Bought a 2003 mille a couple of weeks ago, all seemed well. tried starting a couple of days later and it didn't fancy it. So after a night on the optimate, it started right up. same thing happened a couple of days later, so I initially put it down to a duff battery. One new yuasa 14 battery, new uprated starter solenoid and new iridium plugs fitted. Still she doesn't want to start. :banghead
So whats goin on... turn the ignition on, fuel primes no probs, pull the fast idle leaver back and push the starter.... it just wont fire up.
Sprag is fine, however I have already bought a new one using the KTM part # just in case.
I have noticed that on testing the charged battery voltage using a multi meter, it reeds 13.2 volts...tip top. Up on the dash display it reads 11.7 before pressing the starter...to low. Now would I be correct in thinking that the ignition on these bikes is wired through the clocks and a bad connection into the clocks could cause this drop in voltage and would make the bike not spark :dunno
I have gone through all the rear connections/relays making sure they are good, next step is to go through the sensors and do the same.
I am correct in thinking that if any of the safety sensors like the lean angle sensor or engine stop relay were buggered, the result when you turn the ignition on and press the starter, would be like having the kill switch on and it wouldn't crank over?

Anyways I've got the workshop manual so if its not raining tonight ill be going through everything testing with a multi meter.
Failing that maybe if I get a little Italian and put on some linen trousers with a fedora hat...opera music on and a double espresso in hand, she may be more impressed with me and start up :tounge2

checked, engine stop relay, that's fine and tilt angle switch is tip top, checked with a multimeter all connections at the back of bike and there are no problems so tonight I will be checking all at the front of the bike. any ideas?

The voltage reading on the dash is very inaccurate !, It can be out by over a(1) volt.

Some people have reported an issue with faulty starter buttons and or sidestand/clutch inhibit switches.

I shall have a look tonight, yea the difference between voltage at battery and voltage on the clocks is nearly a volt out so I will forget about that:thumbup, when I press the starter, with the bike in neutral with the side stand down or up the bike will turn over. pulling in the clutch doesn't make a difference to this procedure. Should you have to pull the clutch in on these bikes to start when in neutral?

No in neutral bike should start without clutch being pulled in.

Fast Idle full on and no throttle ?

sound, thought as much.
Yep starting with full fast idle and no throttle. I ve just tried the fuel pump relay on a buddy's rsv and it made it stutter a bit on fueling so ive picked up a new relay from work and will fit it tonight, hopefully its an intermittent problem, otherwise out comes the head torch and multimeter for another late night session of fault finding, this time everything towards the front of the bike

all sorted....turned out to be an intermittent fault with the fuel pump relay.. got it sorted just in time for a midnight thrash...which was brought to an end by the old bill following me all the way home.. sneaky buggers....new front fitted today so will be out on it again tonight :doug

Well done that man...maybe riding like you stole it would not be appropriate

Well my woes have now been confirmed...all my problems were down to a going sprag clutch. luckily managed to grab a deal for the housing, sprag, ring gear, gasket and flywheel extraction nut , all for under £150 so if the weather is on my side this weekend ill be spending my afternoon doing a spot of fettling:smilie
don't worry didn't ride it like I stole it... I think they just didn't like the cut of my jib..

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Santa has come very early this year :doug

after some sexy time in the garage with the beast....old sprag is out , new one in,, this is the worn out items...spring on the sprag was very loose and housing very worn..
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putting fresh oil in tonight and all should be sorted.

wear on starter gear
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