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The TTR250 FAQ web pages -> TTR250 -> Repairs and maintenance -> Reborn....
Post Info TOPIC: Reborn....
Rui Matos Braz


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Reborn....
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Hi all

It's time to post something about my RAID !

I've bought it in last June , with " some "problems 

- engine start , does not start !!

- CDI , burned !!

And lots of small problems but for 400€ ...

It has been a fight to make it work , with the dismont I've found some outher problems 

But after will bring more pleasur !!!

 

 IMG-20150624-WA0003.jpeg

 

 

 

DSC_0052.JPG

 

IMG-20150708-WA0024.jpeg



-- Edited by Rui Matos Braz on Wednesday 5th of August 2015 02:38:49 AM

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Rui Matos Braz


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It's working....... I'ts working........


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Rui Matos Braz


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I'm...........
The motor starter( "eat ") loose all the teeth...
I' m worried about taking the TTR to Morroco.
I' read almost everything about the problem!

But there are a problem... The generator cover does not fit normaly with the starter motor tied.
Do I make me understand?
Is that normal?
Can you help, please.

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TTRfan


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Starter clutch.jpg

Regarding fitting a new starter motor, it is important to check that all the teeth on the starter gear #1 on the attached photo are in perfect condition with no chips or wear.

Also the bearing (#2) and shaft (#3) (and the housings that the shaft runs in) must not be worn or damaged.

The usual cause of damage to starter motors is kickback from a faulty sprag clutch (one-way assembly) #10. If a sprag is badly worn it is important to check that the journal on the starter gear #7 is not worn or damaged. 

 

If it is only the sprag clutch that is worn (the symptom is a bang, rather than a clunk, from the starter gear area when shutting down the engine) then it needs to be replaced.

The kickback can cause the generator cover to crack in extreme cases. The symptom is usually an oil leak behind the housing for gear #1

The cracks aren't always easy to see.

Damaged casing and gears2.jpg

 

It can get worse - see below!

Damaged generator cover 001.jpg

Damaged generator cover 002.jpg

 

Is it this cover that doesn't fit?

Starter_gear_cover.jpg

 

Brian



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Rui Matos Braz


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https://www.dropbox.com/s/74t19wvvusr4le1/DSC_0002.JPG?dl=0

 

The cover that does not fit is the generator cover. 

Does not fit when the starter motor is fixed... 

I have to release the screws to fit. 

Brian you allready send me this to my personal email. Thank you very mutch. 



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Rui Matos Braz


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https://www.dropbox.com/s/ug0b7pcbn00q1fc/IMG-20150814-WA0002.jpeg?dl=0

 

https://www.dropbox.com/s/5p29ig8t0qzylyx/IMG-20150814-WA0004.jpeg?dl=0

 

 

Is this normal?? 

There are some good teeth in One side and in the other side all broken,  two days after.... All broken. 

Can it be from the starter One way (10) ?  

 

 



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TTRfan


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Rui Matos Braz wrote:

Can it be from the starter One way (10) ?   

Yes it can cry

In nearly 100% of cases a worn sprag clutch is the cause of damage to starter gears, housings and starter pinions no

Brian

PS I posted the information I sent you on the forum as it may help other owners biggrin



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Rui Matos Braz


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Thank's Brian.


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TTRfan


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Will the generator cover fit properly if you use the original Yamaha starter motor?



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hanzo


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Looking at your pictures it looks like you have fitted new starter motor .your pictures of original starter motor shows sign of damage caused by a faulty sprag clutch. You need to start at the sprag to identify the cause of damage to starter pinion. I would guess the large starter gear is also damaged number 1 in diagram .if generator cover is not fitting correctly the gears cannot be meshed or starter is incorrect one 😕



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Rui Matos Braz


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Brian, no I did not try... I assume that the New starter motor solve the problem.
My mistake....

Hanzo, Thank you.
I've bought the number 1 before mont this starter motor.... I think its Ok.


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hanzo


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I hope so inspect everything but i feel sure your sprag clutch is your problem. It is the part which fail first gradually causing further damage if left .Unfortunately a common problem in a fantastic bike due to the TTR being used as intended  off road.Not a problem in bikes only used on road amd started once or twice on a ride  .This is why dont leave a failing sprag too long .It was first job I did on my own bike i had a starter that looked like yours! 



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TTRfan


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Invest in a new sprag clutch and perhaps a used starter chosen from the alternatives here and it should be fixed biggrin

It would be worth fitting a magnetic sump plug if you haven't already. This would catch any fine swarf from the shredded starter pinion.

Brian



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Rui Matos Braz


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Thank Brian
I allready bought ( you) One of these...
(Magnetic sump plug).
I' m Just need the sprag clutch.


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TTRfan


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... and a starter motor wink



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Rui Matos Braz


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Yeap.....

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Rui Matos Braz


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https://www.dropbox.com/s/en9k9o9ldshinzk/_20150926_161406.JPG?dl=0

 

Hi 

Almost done... 

Wath a"movie ",  the starter clutch has arrived from totally TTRs and Wath a diference.... 

 

The starter motor is from a Magesty 250 all I need to do is take the "back " and put the another One from the original starter motor. 

 

 



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Rui Matos Braz


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Just to say that the starter motor fits perfect !
With the change of the "rear " , of course .

The bike is working perfectly .



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