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

honda15i · Senior Member

Does not turn the starter

TTRfan · Super Guru

Solenoid sounds healthy so the brushes are likely to be worn or sticking.

See http://ttr250.activeboard.com/t58726320/starter-motor-removing-and-replacing-a-starter-motor-plus-ch/

honda15i · Senior Member

Thanks TTRfan. I will try to take out the starter and check the inside... Let you know later.

honda15i · Senior Member

I managed to take out the starter. Brushes seems to be worn. There are no seals on the starter. I found rust inside.

Two weeks ago I was passing the river. I believe the water touched the starter...

Do you guys know what is the length on new brushes? I'm going to search for aftermarket brushes tomorrow.

It looks to me it should not be a problem to weld copper wire to the metal? has anybody tried welding?

ttboof · Super Guru

Its just a matter of soldering the new ones on, requires a good sized soldering iron at a squeeze a small flame solder and pliars

ive had 14 years of fiting them, should be able to find a similar set as for length im not sure check the springs are located ontop of the spring when assembled if they are too long the springs will be close to the edge and may slip off the side and jam them,

TTRfan · Super Guru

Les is absolutely right. As he says, the challenge is to get enough heat into it to get a good soldered joint.

There may be some photos here that will help you.

Brian

honda15i · Senior Member

I just checked the manual.

Brush length limit:
4 mm (0.16 in)

Brush overall length:
10 mm (0.39 in)

My brushes are 7-9mm length. Seems to be fine. Will try to clean rust and then penetrate with oil.

honda15i · Senior Member

On Friday I went to local shop they sell all kind of starter brushes. I gave him TTR sample and they found similar set of 4 pieces just for 5€. The new brushes were thicker by 1 mm, the size was easily reduced.

The contacts of the brushes were easily soldered. Then I installed everything back and it started!!!

In addition I cleaned the air filter and went to the forest for riding. We did ~120km in the sand, gravel, forest road with full throttle and fuel ended up, then switched on reserve.

It was pulling like a hard bike and eating fuel too :) Total km on weekand ~180km with ~13l of fuel.

I have another bike Honda CBF 2008, I noticed the starter is pretty same, the numbers matches Mitsuba SM 13 12V. The only difference is the + contact it is rotated on CBF.

Cheers.

TTRfan · Super Guru

Cubber · Super Guru

Thanks for sharing the details.

It gives the rest of us something to aim for.

Martyn