A forum for owners of Yamaha TTR250 trail and enduro bikes!

maybe the fried Solenoid is not the cause but the consequence of a faulty Start button ?
on my chineze honda clone I randomly ran into this kind of trouble: the contacts inside the button were cooked and connected while riding. The funny part of my story is that to start that bike one has to press simultaneously on Front brake & start button. Stopping on traffic red light was funny.

or the wires going from that start button with faulty / cracked insulation ? - may produce the same effect if 2 wires shorted under handle bars.

Re- check the solenoid again to be sure it is not already damaged (disconnect wires, check continuity, link to button only then trigger it many times, try to load it with a small load drawing 4-6 Amp, like a 55W bulb).

EDIT: asking around I found out that a partially shorted starter motor can fry/ damage a solenoid. This is applicable to Chineze street bikes sold in my area. Dealing with these make us encounter ANY trouble once every 6 months to 2 years, kind of troubles that you may never deal with in entire life of a branded bike

Hi Brian

Checking all wiring at the moment , whilst doing this i noticed the carb manifold stub had parted company ,( new item ordered from you arrived this morning many thanks ). Starter button cleaned and checked ,solenoid checked all ok . Starter powered up with a power probe and cranks normally, do you think new solenoid may have been a bit sticky?

 for future reference to isolate the cause just disconnect the switch wire from the solenoid (small wire ) if it still cranks its the solenoid , if not then its a matter of checking the wiring switch ext