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The TTR250 FAQ web pages -> TTR250 -> Repairs and maintenance -> TTR 250 won't run in gear
Post Info TOPIC: TTR 250 won't run in gear
Flying Dodo


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TTR 250 won't run in gear
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Having just rebuilt my TTr top end it all runs biggrin but only in neutral cry , as soon as I put it in gear the engine cuts - it won't restart or even turnover except in neutral - so how should I eliminate the problems to find the source??

I assume it's either a sensor in the gearbox, side stand or clutch switch but where should I start and what procedures?? I've unplugged the side stand switch but that doesnt help.

Any suggestions appreciated!confuse



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Provence FRANCE, 2005 TTR250 (x2), Harley 883 for the roads. Oh yes and the wife's XT125X.
Markvan


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If the side stands unplugged the wires have to be looped. There is alot of imfo if you hit the search button. Maybe type in the search box : side stand switch.:  some members have bypassed all the safety switches. 



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TT-R250M


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Assuming you are talking about the blue TTR in your avatar- The gear box does not have a sensor other than the neutral switch. It is obviously working if it starts in neutral though.

The side stand switch does not need to be bypassed, if I disconnect it, it starts and runs as per usual.

Do you have the side stand up when it cuts out?

The TTR is fitted with a two-way starting circuit cut-off circuit which consists of the clutch switch and the neutral switch. If either of the conditions is not met it will not start. However, this will only effect the starting operation not the ignition and will not effect anything once the bike is started.

The side stand switch will cut-off the ignition if the side stand is down and the bike is in gear. Disconnecting it should have sorted that though.

It does sound like your clutch switch is not working as pulling the clutch in should start the bike. I would suggest that you disconnect it from the wiring harness and run 12v from a battery into the clutch switch while testing the other receiving wire with a multimeter or test light. Pulling the clutch lever in should give you 12v at the other clutch switch wire. If it does not, it is not working correctly. Although, this will not help with the ''TTR 250 won't run in gear'' problem.

Jarrah



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Flying Dodo


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Hi All

Thanks for the advice - it was the side stand - I like Jarrah thought if disconnected it would run but it needed the sensor by passed, Thanks All and to Brian who pm'd me with similar advice.

Now to take it out for a gentle run and see if the new head piton rings etc. all hold together!

Cheers
Dave

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Provence FRANCE, 2005 TTR250 (x2), Harley 883 for the roads. Oh yes and the wife's XT125X.
TT-R250M


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Flying Dodo wrote:

Hi All

Thanks for the advice - it was the side stand - I like Jarrah thought if disconnected it would run but it needed the sensor by passed, Thanks All and to Brian who pm'd me with similar advice.

 Cheers
Dave

 Wow, my bike must be special then lol. Either that or a wire crossed. smile Not sure how as I have checked the electrical circuit many times and all is functioning as it should. I don't remember bypassing it in the wiring harness when I rebuilt my bike???confuseconfuseconfuse Not that I see this as an issue as the side-stand switch uses AC current. It would not do damage if earthed to ground and I'd know about it if it touched DC.   It has me pondering though. smile

At least I know to advise others of this apparent problem that everyone but me seems to encounter. wink

Glad you got it sorted!

Enjoy!

Jarrah



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TTRfan


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Bypass connectors.jpg

 

It is quite common for me to find the stand switch missing on my rebuilds and a bypass connector fitted to the loom as shown above.

I got quite a collection of them now as I prefer to have the side stand switch fitted after a couple of near-nasty accidents from driving off with the stand down disbelief

Glad you got it sorted Dave - enjoy your ride biggrin

Brian



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TT-R250M


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Yes, Brian, very easy. The other way would be to earth the feed wire it to ground (much harder). I am actually half glad mine does not work as relying on a side-stand switch for ignition does not seem right to me somehow. On the other hand, for owners that are forgetful it may come in handy. smile

Still has me stumped why mine is so special though, I do not need the side-stand switch or bypassing it seems. biggrin Maybe the PO has done something unseen to my harness like joining the wires together? I can see myself investigating at some stage out of curiosity more than anything else. smile

Jarrah



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Flying Dodo


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25 gentle miles and seems OK so far - but I will have to sort out the carb next

Dave

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Provence FRANCE, 2005 TTR250 (x2), Harley 883 for the roads. Oh yes and the wife's XT125X.
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