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

T Mozza · Member

Help Diagnosing issue (Bike died on ride, battery swollen, new battery, wont start)

TTRfan · Super Guru

Hi Tyler

It sounds like a battery/charging issue to me. What happens if you grab another 12v battery that you know is good and attach jump leads to the TTR's and hit the starter button?

Brian

ttboof · Super Guru

Old battery may have just died and it's a coincidence that the starter brushes are also crook

Brians idea is good if it cranks with jumper leads the new battery may be discharged and it could be a charging problem

Only thing other than an internal fault that might make the battery swell up us over charging

May be evident as lights brighter than usual or blown globes best check is a volt meter with the bike running the voltage shouldn't sneak above 14.5v ish

Only way the starter could cause an issue with the battery is if the solenoid stayed closed which means no click just crank when the battery is connected

ttboof · Super Guru

Just a but of info a fully charged battery sitting will show about 12.5v 11.5v should start to crank may be a bit slow 10.5 would be discharged to low to do anything

Stick with Brian's check use jumper leads and see if it goes if still intermittent bridge the solenoid heavy wires and still no go could be brushes

If it fires up check it charges back up to 14v in a few minutes

If it doesn't may not be charging if it keeps climbing the regulator isn't working

If your checking the starter unbolted make sure the body is earthed to the motor

T Mozza · Member

Attached jump leads from my car to the TTR, same ordeal, starter motor ticked over a few times, then refused to turn at all, did throw a few sparks though but that may be to it not being secured properly in the housing.

Could it be a problem with the solenoid? Its the only thing that sitting between the battery and the starter. Tomorrow Ill be able to take a video if that helps explain the problem better, Ill put the starter motor back in place and take on if so.

Can't really think of what else it could be when its not even turning over properly from my car.

Cheers,

Tyler

-- Edited by T Mozza on Monday 1st of April 2019 11:07:06 AM

T Mozza · Member

Sorry ttboof page didnt load your reply,

Will try all those trouble shoots in the morning! Thanks heaps

ttboof · Super Guru

Sounds like you have ruled out the battery . Yes it needs a good connection to the motor will cause a few sparks or a no go

If it's still intermittent with jumperleads and a good earth connection try bridging the solenoid across the two main wires and it should spin each time

If still intermittent would start to look like brushes avoid hitting the starter as the magnets are super brittle

T Mozza · Member

Just made a connection with something you said earlier ttboof. You said the battery should show no less then about 10.5v. I had the battery and before I put it in it read 12.4v and then after turning ignition reading dropping to around 8v.

Im just measuring DC on the multi meter and what you said has lead me to believe this shouldnt be happening.

Can't stand these eletrical demons!!

T Mozza · Member

Just put starter motor back in and all seems in order. Battery charged to 14.06v and didnt go any higher. Not sure what the issue was but i hope it doesnt arise again.

Thanks all again for helping with trouble shooting

ttboof · Super Guru

Sounds like its charging OK. They are only small batteries only takes a few cranks to drop thier open voltage reading.

If it fails again before you pull anything apart

Take note of you press the button and you hear a click

A the lights dim right down and no crank. Maybe the battery has discharged.

Charge ride and before parking disconnect the battery and see if holds charge when reconnected after a period of time

B it clicks and the lights don't dim or only slightly. Indicates low current draw. Only leaves solenoid or starter (most likely brushes)

Hope this helps I like lecky stuff worked with it for a long time. Not complicated just can't see the stuff

JOHNYBOY · Super Guru

swolen battery is overcharging it will also smell if you remove the tops a farty smell be carefull not to spill any acid if you do wash thorougly with water to dilute BE CAREFULL JOHN

Fat Leopard · Veteran Member

I had a situation nearly identical to this on my wife's TTR125 (minus the swollen battery). I mention it now only because you may not be at the end of this story. I followed a similar diagnostic path as outlined above and after a meticulous cleaning of every electrical connection from the battery+ to the starter and from starter to ground, I had it solved... I thought. It was mentioned above to jumper the starter solenoid if your problem returns - this was the key for my issue. My starter relay was failing intermittently and a jump across the relay confirmed the diagnosis. Once the relay was replaced, the issue never returned. The TTR125 starting setup is practically the same as the TTR250 (including the dual start) and the relay may even be identical.