TE 250/310 xlite starter issues...

No problem.

To be honest, I've been following this thread and as soon as my e-start didn't work I thought the worst.
I should have checked the simple stuff before (drinking 6 beers and) posting

2012 TE310 owner here - NSW Australia. I had the e-start stop working, all fixed under warranty.

I took the bike to the dealer where i purchased it, they replaced the worm gear and starter motor. All covered under warranty and not a cent from me, great service.

This is the only issue the bike has had in 1000 single track km's.

Just installed the starter service bulletin parts installed into my TXC310R machine (hope that helps).
Further inspection reveals sprag clutch bearing surface of inside of flywheel is visibly and tactally pitted and in my and my mechs opinion its cause for rejection, scratch one expensive ignition flywheel.
I'm am always relaxed and understand that machines break ( I work on/with Aircraft) , but I'm starting to be annoyed and ready to vent about this new BMW re-engineered bike. If I bought a KTM I would still be riding it not have it in pieces on my work bench. My Italian black head 2011 TE310 has been stone reliable.

No problems with mine so far but it's more and more obvious several model years had suspect parts in these 250/310 starter systems. At one point they issued a general service bulletin/recall that only involved certain serial #'s but it really didn't match up with failures in 2011, 2012, and 2013 models. I would like to have the parts replaced or at least supplied for future replacement rather than dealing with a problem they'll claim is out of warranty.

Got both bikes back from the dealer. Replaced starter on the TE250. That's a complete new top end and now a new starter, since December 2012. The TE310 showed no problems with the dealer. Keeping the fingers crossed with that one. Still love both bikes. Wicked fun!!!

The issue with my bike is hopefully over prior to the starter issue i had an issue with the water pump seal and the bike ran very hot as the coolant leaked into the motor this meant the bike ran very hot on a couple of rides i just topped up the level thinking this may be normal - no sign of boiling as the coolant was not coming out the radiator relief it was being used up thru the engine - this over heating seems to of caused wear on the tips of the exhaust valves and this explains the valve clearances increasing and the auto de compressor not engaging and causing the e start mechanism to jam. So top end re build new exhaust valves and piston ring set as the bike was now also using oil valve seals also replaced and the bore was honed.

So the whole starter issue seems to be caused by the water pump seal failing causing over heating and excessive wear of the exhaust valves.

If your bike is using coolant and it is not boiling/steaming from the pressure relief then quickly check that little seal on the water pump as it can fail - being up high on the motor it can dry out if the bike is not ridden regularly.

When the valves wear the clearances get too tight and the valves don't close properly which cause the hard starting. Never happened to my husky but it happened to my Honda.

Not in this case the clearance increased so the auto de comp was not being actuated - the wear was on the tip of the valve not the seat as you mentioned with the honda. the valves in the husky are far superior to the ones in the honda - the problem with my bike was caused by the overheating issue.
thx

Right...the X-lites like that left side exhaust valve a little tight...or else the auto-D does not hold the valve open enough.

valve clearances increasing has been quite a learning experience particularly with these new generation 4 strokes - the valve clearances increasing was noticeable in some of the older four stroke engines and this waS caused by carbon build up but even this was rare.
Anyway early days but the bike seems to be OK

Just picked up my new 2013 TE310R from the dealer this Friday and took it for a 2hour spin. Everything worked flawlessly.
Yesterday I ran very well too for about 1 hour of riding time. (Even survived its first little crash, but ran well after that). After a short break to grap some food, I rode for about 5 minutes and then stalled it on a small hill (too slow). I tried to e-start it like I did all the time before and the e-start just runs freely, as if not attached via (worm gear?). You can clearly hear the starter moving...tried to kick-start, but would not start the engine either. Before the kick-starter worked after 1-2 kicks...

At least that is not a common problem, you guys discribed...

The TE310R goes back to the dealer on Friday, to solve that problem. Maybe it is just a gear disattached from the starter which effects the kick start by some way.

Probably, the nut backed off the gears.

Would that be a easy fix? Just put the nut back on or could be something damaged?

There is also a woodruff key which is probably broken... Anyway, you should check the whole mechanism including the free wheel. For that you have to take out the fly wheel. Zipty is selling a puller for that and a tool for fixing it while torquing.

Ask your dealer if there was an update for the worm gear and corona wheel and get the valves clearance checked.

Check this:



It's the ring gear that is driven by the worm gear. These two parts cause 90% of the problems of the xlites. You could buy it separately for 2011 and 2012 and now you can only buy it together as a kit. After years they were not able to eliminate the problems, pretty stupid...

The issue was the nut on the crank which holds the pulse wheel in place, who has loosened up by itself.
Torgued it with loctide, so hopefully it won´t happen again. No damage on the crank or pulse wheel. Lucky me

On my 2010 the starter struggles to turn the engine over hot or cold. I stopped using the starter and now just kick it. Starts right up as long as its in neutral. I've tried lessening the gap for the decompression. I think its just a weak starter.
Has anyone tried "fixing" a bad starter? Is it even possible?

I have had mine rebuilt, but still have the same issue. I just kick as well...

I won't waste money getting it rebuilt then.