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

Lurkville · Member

TTR single click upon e-start

Lurkville · Member

update-

tapped it with a hammer. but it is making terrible inconsistent noises. it has made loud clicks for some time, but would start and didnt sound like it was dying.

vimeo.com/324302410

Cubber · Super Guru

Is the battery OK? confuse

Sounds as if it could do with a charge to make it spin more.

Try a jump start from another battery, say a nearby car, with jump leads connected the right way!!

Martyn

Lurkville · Member

the sound of the starter sure is clicking loud too... and tapping the starter made it go from a click to engage.

Base · Senior Member

Check the voltage of the battery under load/whilst starting. Could be new battery time? If the voltage drops significantly your battery may have gone bad.

ttboof · Super Guru

If the lights don't dim when you try the starter

Then most likely it's the solenoid or bushes in the starter

First check is to bridge the two big terminals on the solenoid. If it cranks, it's the solenoid

Next step check for power at the starter terminal when it clicks if yes most likely the brushes

A light tap might get a start out of it if it's brushes

But don't hit the starter hard as the magnets are brittle and break easy

TTRfan · Super Guru

Les has given good advice Dan.

If the motor doesn't spin over when you bridge the solenoid terminals then it sounds like the brushes are sticking or worn.

In which case, this thread might help you.

Brian

tom13 · Senior Member

ttboof wrote:
If the lights don't dim when you try the starter

Les- and they're fading. Is it a brush?

ttboof · Super Guru

tom13 wrote:
ttboof wrote:
If the lights don't dim when you try the starter

Les- and they're fading. Is it a brush?

If they are fading noticeably could just be a battery

If it's brushes as there is no curcuit the lights shouldn't fade out maybe slightly dim

Lurkville · Member

would I be bridging these two terminals? what wire do I use to bridge them

ttr steve · Super Guru

between the 2 bolts on the back of the solenoid, using a screwdriver would be fine

-- Edited by ttr steve on Saturday 16th of March 2019 01:21:35 PM

tom13 · Senior Member

"If they are fading noticeably could just be a battery

If it's brushes as there is no curcuit the lights shouldn't fade out maybe slightly dim "

The battery is new charged 13.8V. The starter does half a turn of the shaft only and still has no strength. The lights go out. The battery then has 12.3V and no longer rotates.

-- Edited by tom13 on Saturday 16th of March 2019 02:08:44 PM

Lurkville · Member

It would simply just click, but would start to crank if i tapped the starter, but i couldnt get it to start. Does this rule out the solenoid?

I will try bridge the solenoid, like steve said with a screwdriver, just touching over the two bolts?

"Next step check for power at the starter terminal when it clicks if yes most likely the brushes"
--whats the best way to check this, with a voltage tester?

Thanks guys-- when it comes to these electric issues i am clueless

Lurkville · Member

https://ttr250.activeboard.com/download.spark?ID=1612449&aBID=139305

/download.spark?ID=1612449&aBID=139305

Is this the lead to check for power at the starter?

ttboof · Super Guru

If it's attempting to turn with a light tap and the lights aren't fading right out

It's starting to look like brushes

Only taking the starter off and apart will tell but not a difficult job.

Use Brian's how to if you decide to have a look .

One last check that is the positive lead on the starter check it's not loose as it can give the same symptoms as worn brushes

That is a click and no or limited crank

-- Edited by ttboof on Saturday 16th of March 2019 09:31:46 PM

Lurkville · Member

Wow thanks so much. I’ll give that a shot. Im happy there is so much documentation and support on this forum. Just one question- which would be the positive lead on the starter be located?

ttboof · Super Guru

There's only the one connection on the starter it has the lead from the solenoid attached

On top at the back an 8mm nut if my memory serves me correctly be careful not to twist the post /bolt

-- Edited by ttboof on Sunday 17th of March 2019 01:27:52 AM

TTRfan · Super Guru

Lurkville wrote:
https://ttr250.activeboard.com/download.spark?ID=1612449&aBID=139305
Is this the lead to check for power at the starter?

Yes - that's the power lead from the solenoid. 10mm nut.

Lurkville · Member

Alright guys, ready for an update.

Pulled the starter cover- PO stripped one of the allens and had to hammer a star bit in order to get it off. Off to a great start!

As soon as I popped the cover, tons of metal shavings

Decided I'd better pull the starter and get a closer look.

First I checked all the leads and made sure they were a tight fit, but at this point it seemed obvious it was the starter.

a little rusty, but everything was secure.

STARTER:

-removed the exhaust header

-removed 3 banjo bolts to fitting

-removed clutch bracket

-was unable to get a wrench on the lead at the top of the starter, aggravating that I couldnt get a wrench to fit and I do not have a means to grind down an extra 10mm ..

-removed the starter with the lead attached and detached it at the solenoid end

Can see where all those metal shavings came from....

Bits of magnets all inside !

So that's that. I am still aggravated about this lead up top. It seems it will need to come off if i'm to replace any of these components(?)

Besides grinding down a wrench, is there another way to take this damn thing off?!

TTRfan · Super Guru

Hi Dan

That is bad news cry

The most common cause of such damage is a worn sprag clutch which allows the engine to kickback when it is switched off and this can strip the starter pinion and likely damage the small starter gear teeth (Gear 2). In more extreme cases the kickback can also crack the generator cover.

See http://www.ttr250.com/Sprag_replacement/TTR_sprag_replacement.htm for help in fixing the problem.

Also, it looks like the brushes have broken up rather than the starter magnet.

Brian

Lurkville · Member

Thanks Brian. That is definitely a more invasive task than i had anticipated. I had ordered a used starter off ebay for 45 today hoping that I could just swap a "new" one on. However, if youre saying the sprag is worn, I'm assuming this would just happen to a replacement if I put it in there?

Lurkville · Member

Given that I have ordered a used starter that is claimed to be in good working condition and not worn, I should only need sprag clutch (4GY-15590-00-00) and follow the tutorial?

Any other parts besides the mentioned flywheel puller and the sprag?

TTRfan · Super Guru

If your sprag is worn and not replaced it will almost certainly damage your replacement starter.

Have a read through the tutorial and it will give you an idea as to what other parts might need replacement, depending on their condition, such as Gear 2 if any teeth are damaged by the starter pinion (very likely!), Gear 3 if the boss is worn or damaged, and the generator cover gasket. Check the generator cover carefully for any sign of cracking or damage from the swarf.

The flywheel will have collected most of the starter pinion swarf so make sure that is properly cleaned off. You are also like to find some in the sump that will need cleaning out. Check the oil filter for shiny bits and clean/replace as necessary. It might be worth fitting a magnetic sump plug to catch and remaining swarf that might be floating around in the sump.

Brian