Any one have issues with the starter failing? On occasion, but now more frequently the bike will try to turn over, but doesn't and just makes a whining noise. It sounds nothing like a dead battery " click click click". I've got a shorai battery in the bike now.


The only thing I can think that's happening inside the starter are:

1. The gears are not meshing together correctly which creates the whining noise.

2. The winding withing the starter are starting to fail.

Thoughts?

Bike is an 09 KLX250s w/ 8,000 miles.

 

If it sounds like the starter is spinning, there's a problem between the starter and the gear on the engine clutch. Maybe the one way clutch , #13194 and 13216

http://www.bikebandit.com/oem-parts/...8849#sch579787
See Electrical, OEM, "Starter Motor"

Ride on
Brewster

 

Do you have the choke on when starting?

Unless its really warm out, I still have to use the choke to start the bike,

when I forget to, the starter makes a noise,

but always start after being choked or throttled.

is your bike not starting at all? or just a noise.

 

I think in the starter clutch there are some kind of ratchet mechanism, if it is not catching that would allow the starter motor to rotate and the engine not turn over.

 

I would look at the starter clutch/torque limiter. The limiter is housed behind the small cover on the l/h side of the engine-remove the 3 bolts that secure the cover and you will be able to access the limiter. Don't lose the thrust washers that fit on each end of the shaft.
The limiter has two gears that are coupled on a common shaft-if it fails it will allow the gears to spin independently of each other and won't transmit power from the starter motor to spin over the engine. If the limiter checks ok then there is one other part on the engine that can produce your symptoms. After you remove the torque limiter you will see another gear that the limiter meshes. That gear should free-wheel in one direction and not move in the other. If it seems to work like that it means that the one-way clutch(sprag assm) on the alternator rotor is working normally. If the gear spins freely in both directions then the sprag has failed and that's what is causing the no start problem. Good luck and read pages9-21 and 9-22 of the service manual for more detailed info.