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I'd just flow some solder in all the crimps of the connections that supply power to the starter and back all the way from the battery. (batt terminals, solenoid, starter connector lug, grounds, etc)
Had to do it on the Vmax. Ran like a whole new bike after 45 minutes with a soldering iron and a raging erection.
Last edited by TheIglu; 05-09-13 at 02:48 PM.
2021 KTM Duke 890 R
2020 BMW R1250GS Adventure Exclusive
1982 Honda CB750F Super Sport
As long as they lugs are crimped, solder is a good idea.
I would not recommend just solder though, that can fail spectacularly if the lug heats up from a poor connection and releases the battery lead lead to flop around in a mostly metallic environment that's connected to the other side of the battery...
If you dig into it, you'll find hot starting is a common problem with the '03 and '04 CBR 600RR. Try the simplest solution first: get a known, fresh, high quality battery, and perhaps replace the r/r with a heat shielded one from a '05 or newer to help keep the battery in good shape.
Being an RR with a bias towards light weight track performance, and not everyday riding, the battery spec is just barely adequate for use as a daily rider. A gas stop, a snack stop, and a stop at the bank, and your battery might be done for the day, or at least until it cools way down and the electrical resistance in the whole system decreases a little.
Slightly bad grounds, a starter motor that has slightly higher resistance due to heat or age, radiator fan running, etc. can all combine and contribute to the problem and become too much for the battery.
A fresh, high quality battery fixed my '04 600RR hot start problem. It re-starts right away at 200 degrees plus.
Can you get a few guys to lift it up?
It's all water under the bridge, and we do enter the next round-robin. Am I wrong?
i had mentioned to mike while we were brainstorming a bit on monday that i noticed that his exhaust is not shielded (full aftermarket system) and was thinking that maybe the hot exhaust pipe thats running right past the battery may be heating it up. i suggested some sort of heat tape/wrap. we discussed the possibility of the R/R but the fact that the bike restarts (seemingly) without issue once it cools leads me to think maybe not.
When I start my KTM in the morning, rules are broken. Its inevitable...
01 SV650S (RC51 eater)/07 690SM /03 300EXC/14 XTZ1200
TRACKS:Firebird/NHMS/VIR/Calabogie/California Speedway/NJMP/MMC/NYST/Palmer/Thompson/Club Motorsports
That's a good bit of info about his particular bike. If he has taken out the factory exhaust and heat shield, a replacement heat shield or tape under the subframe should help a lot, as the heat rising from the exhaust will tend to cook the battery and cause premature failure.
LRRS Am #331
Graphic Tailor / Woodcraft / Armour Bodies / Suomy / Cycle Performance Autobody / Shorai / ChickenHawk Racing
The 03 600RR had this problem from the factory. I had two of them, they both had the same problem (and while filing warranty claims, I heard many people with the same issue) but I crashed them both and got an '04, never had the problem with the '04. If I were researching this problem, I'd look at the part number changes in the charging/electrical system between 03 and 04, because Honda definitely fixed it. I suspected the rectifier was forked, sorry I can't be more helpful.
Now that summer's over, how did your solutions to that problem work out?
I'm allergic to Xeljanz you dick.
It's pretty awesome when a 7 year old thread gets bumped and the OP provides a solution that solved the problem.
Last edited by Chippertheripper; 07-03-20 at 05:53 AM.
Cliff's Cycles KTM
NETRA enduro B-vet
Close your eyes, look deep in your soul, step outside yourself and let your mind go.