KTM 400-660 LC4 1998-2005 Repair Manual page 137

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Checking the starter relay
– Remove the seat and the right side cover and disconnect the
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combination connector
– Disconnect negative terminal at battery and the two cables at the
starter relay.
– Connect the starter relay to a 12 V battery as indicated in the
diagram.
– Check continuity between terminals
Reading: 0 Ω OK
Reading: ∞ Ω defect
NOTE: The response of the starter relay is accompanied by a faint
clicking sound.
Checking the electric starter motor
– Switch off the ignition.
– Disconnect the negative pole of the battery and remove the electric
starter motor.
– Connect the negative pole of a 12 V battery to the housing of the E
starter motor and briefly connect the positive pole of the battery to
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connection of the electric starter motor (use thick cables).
– The starter must turn as soon as the circuit is closed.
– If this is not the case, replace the starter.
Checking the neutral switch
– Remove the chain cover.
– Connect one terminal of a test lamp to the positive pole of the
battery and the other to connection
– The test lamp must light up when the transmission is switched to
neutral.
– The test lamp must go out as soon as a gear is put in.
Trouble shooting in the electric starter system
When the starter motor fails to turn upon operation of the tip switch,
perform the following checks first:
● Is the ignition lock switched to
● Is the emergency OFF switch in the position
● Is the neutral control lamp on while the ignition is on?
● Can the engine be started with the clutch pulled?
● Is the battery charged?
● Has the main fuse blown?
● Check the auxiliary starting relay
● Check the starter relay
● Check the starter motor
of the starter relay.
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and using an ohmmeter.
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of the neutral switch.
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7-26E