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The TTR250 FAQ web pages -> TTR250 -> Repairs and maintenance -> Main Switch Problems ....please help !!!!!
Post Info TOPIC: Main Switch Problems ....please help !!!!!
dj9ten


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Main Switch Problems ....please help !!!!!
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Hello all ....I'm new to the group ....I've owned a 99 ttr250 for about 2 weeeks now ....I bought it non running with no wiring harness basically (original one was rigged up some crazy way) .....so I grabbed my multi meter and downloadded manual ....I checked every thing and ended up replacing the ignition coil and starter relay......when it all boils down to it my main switch isn't functioning correctly ....the red button works but the grey one doesnt .....I can connect a direct lead from the positive battery terminal to the top of the blue wire on the main switch and the engine will turn over just once even if I hold it there ......so I cut the blue wire right above the connector (on the switch Side not the harness side) and when I connect that directly the engine will try and turn over as long as I hold it there  (Multiple times).....only problem Is now the battery starting to smoke  when i try it .......does it sound like short somewhere ? I also tried looping the 2 red wires and connec just the blue wire to the battery (didn't work) and I tried connecting all 3 (red,red,blue) to the positive terminal and no success .....any suggestions or insight on how the ignition switch works ?



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TTRHead


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cant u buy the loom i am selling and rig that up? got both handle bar switches also..

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dj9ten


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I just bought a new wiring harness .....and with the switch cut I connected the 2 red wires together and the blue and black wire to a new push button switch .....when I press the button the engine only turns over one time no matter how long I hold the button .....if I hold a lead directly from the positive battery terminal to the starter relay the engine will turn over as long as I hold it ....what coulf be the problem? in the picture the 2 red wires have conductivity and the black and blue wire are set to the button wish is connected to the positive terminal 

 



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TTRfan


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Very puzzled by this one!

The starter switch (grey button) is a very simple assembly and the contacts can get dirty. Just open the switch and scratch the contacts (with a small screwdriver in between the spring - it'll be obvious what I mean when you have opened thes switch) and try it again.

Could you re-post the photo please as I can't open it.

Many thanks

Brian



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dj9ten


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I tried that ....to no avail ......before I cut the switch at the main switch I tried touching a + lead from the battery directly to where the blue wite  is soldered onto the grey button ....the bike sparks and turns over once ....i have to keepin repeatedly touching it to get it to turn over and spark more than one time  .....if hold that same + lead to the starter relay the starter turns over as long as I hold it (like normal) but I don't get spark....

in the picture I cut the wires from the main switch aboyt 2-3 inches BEFORE they plug into the wiring harness ....I looped the 2 red wires (complete a circuit) and hooked the black and blue wires (complete circuit)  to a push button switch That connecets to the battery + terminal and when I push the button I get the same response (complete the circuit) the bike still just tuns over once no matter how long I hold it .....



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dj9ten


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I take that back ....the culprit may be a dead battery .....I woke up this morning and the button worked ....it gave me  few chugs this mornin after sitting all night ....its strange because when I Hooked the bike up with jumper cables yesterday it wouldn't get any better ....battery voltage reads exactly 12 volts 



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dj9ten


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And shouldn't the touching the blue and black wires start the bike ? If the 2 reds are connected and the black and blue are connected why am I having to run the black and blue wires directly to the positive terminal in order to get it to fire ? Shouldn't I be able to just touch them together and complete the circuit in order to get it to spark ?

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dj9ten


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Thanks to all that helped ....all the switchs on the handle bars had gone bad.....I hard wired a new kill & ignition switch and also looped the clutch switch and neutral switch ....bike turns over and sparks fine now I just got work on gettin it to actually start

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TTRfan


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Good to hear you got the wiring and switches sorted!

Brian



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