Facing starter motor issues on my preowned KTM Duke 390 motorcycle

The starter motor works, but the connecting point and nut are rusted.

BHPian shadowrider recently shared this with other enthusiasts.

Hi, I recently purchased a 2013 Duke 390, and it's been a blast so far, except for the starter motor . Mainly there are two issues, the starter motor cable is way past its life, the insulation is torn and every time I press the starter smoke will arise from there. So, bought a new cable.Part number JG402236.

Here's the cable with the insulation torn and from where the smoke arises.

Now the second part is where the real trouble starts. The starter motor works, but the connecting point and nut are rusted. Also, the rubber covering of the current cable somehow got melted to it. Now, is the starter motor repairable? When enquired at the SVC the new one for bs3 is priced at 8000rs. I was also wondering if the Dominars will work. (noob here).

The bruised-up started motor.

Here's what BHPian ebonho had to say on the matter:

Try soaking it in WD40?

I have a favourite set of pliers that are jammed up like this with rust. WD40 did not work.

I have the same issue with the bolt of the silver heat shield of my silencer. It jams solid because of corrosion/oxidation and the mech says if you try to get it off, because it has been heat cycled so many times, it will just shear off leaving you to get a specialist to remove the left over threaded piece.

Cheers, Doc

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