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The TTR250 FAQ web pages -> TTR250 -> Repairs and maintenance -> STARTER RELAY - aka solenoid
Post Info TOPIC: STARTER RELAY - aka solenoid
tracker


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STARTER RELAY - aka solenoid
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The TTR wouldn't start,a clicking sound was coming from the starter relay.I removed and cleaned the terminals but still the same,so off to dealer who wanted over £45 for genuine Yamaha part.So to the breakers i thought,while drooling over the new bikes in the showroom i told them about the relay,i sold one of them last week says the man,it looks exactly the same,its a pattern part for a CB200 cost £12.52.So i ordered one,will let you all know if it works.



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TTRfan


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It will be good if it fits smile

Is this the one?  

http://www.patternparts.net/p-Starter_Relay-37744.aspx

Brian



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tracker


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Picked up relay today,the diameter was slightly larger but managed to fit it in the original holder.the connectors were different but that was easily fixed.All back, the moment of truth had arrived,the bike fired up first press of the button.So a saving of over £35 on Yamaha prices.

 

http://www.patternparts.net/p-Starter_Relay-37744.aspx

Yes Brian thats the one.



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Deano


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My '02 TTR makes a helluva clatter from the "starter area" but usually starts.

Rode it saturday, ran fine!  Sunday morning, same clatter but just will not start.  That was a week ago and still no luck.  FRUSTRATED!

Anyone have any thoughts on this.  Done all I know to do but I'm not a gear head.

Just know the basic maintanence stuff and simple things.  Hate it when i cant fix my own stuff and have to pay someone else to do it for me!



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domski1


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http://www.dirtybiking.co.uk/features/tech_stuff_2005_starter_rebuild.htm 

Have a look at this link, it sounds like you may have a big bill coming your way unfortunately.

Welcome to the forum,

Adam.



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oshanrube


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it seems to be a very common problem with the electric starter. i just brought my bike back from the dealer it cost about 180$ for the sprang clutch(very small part but ridiculously expensive about 135$ (japan genuine)) and fixing it .anyway it starts and runs like the monster it used to be :D i was wondering, is it a worthy upgrade to go for a 500$ kick start kit? before it comes to anymore trouble with electric start?

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domski1


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I may stand corrected but I think even with a kick start fitted and used as the main way to start the bike the sprag clutch will still wear as the wear is caused when the engine is stopped and there is a slight kick back and the rollers on the sprag are moving as the engine is running. I think the sprag should be changed as a service atem say every 5 years or so to prevent further damage.

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oshanrube


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i was wondering this many times. which was is the best to stop the engine, turn off the key or stop the engine with kill switch?

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domski1


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It won't make any differance at all either switch does the same job, I always use the key as then the lights are switched straight off and it saves the battery.

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Cubber


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I have heard it's best to stall the engine (in gear + brakes on) and this reduces any sprag spin/jerk.
Don't know how long your clutch lasts but at least it's one way of preventing throw back.
Martyn

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oshanrube


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martyn wont stalling with gear be making impact in clutch?

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Cubber


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Definitely will impact  blankstare - but the clutch is bigger, stronger and more easily repaired (at a more affordable cost) than the starter sprag. confuse

Martyn



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TTRfan


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domski1 wrote:

I may stand corrected but I think even with a kick start fitted and used as the main way to start the bike the sprag clutch will still wear as the wear is caused when the engine is stopped and there is a slight kick back and the rollers on the sprag are moving as the engine is running. I think the sprag should be changed as a service atem say every 5 years or so to prevent further damage.

The starter gears could be removed so no harm done if there is kickback wink 

Also, if they are in good condition, they would be worth selling on to subsidise thecost of the kickstart kit biggrin

Brian



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Dean6767


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Can anyone tell me the part number or link me to this starter relay as I'm struggling to find it.

Dean

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TTRfan


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See http://ttr250.activeboard.com/t58918685/solenoid-replacement/

Beware the after-market solenoids. They aren't up to the job and the contacts melt such that the starter is left permanently spinning no

Use a new or s/h genuine part e.g. as here

Brian



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ttboof


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RE: STARTER RELAY - aka solenoid
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TTRfan wrote:

See http://ttr250.activeboard.com/t58918685/solenoid-replacement/

Beware the after-market solenoids. They aren't up to the job and the contacts melt such that the starter is left permanently spinning no

Use a new or s/h genuine part e.g. as here

Brian

 Agree the cheap copies arnt worth the risk. 



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TTRfan


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Solenoid_dismantled4 numbered.jpg

 

The copper contacts on the after-market solenoids overheat and fuse together - parts numbered 3 and 4 in the photo above.

Solenoid_dismantled5.jpg



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ttboof


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I've also seen the same problem in a lot of cheap starters in Toyota hilux and landcrusers the insulation is only cheap plastic and once the contacts start to fail the heat melts the plastic into a nice glue to hold the solenoid closed 



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