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Post Info TOPIC: Help please: weird starter/no-spark issue


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Help please: weird starter/no-spark issue
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Hi all,

Two weeks ago my blue TTR (2003) was working fine: I did a 135k on/off road trip, parked up and when I went back to the bike a day later it wouldn't start. The starter would turn but there was no spark. Being a lazy sod I took it to my local Yamaha dealer. They did static tests and said the stator was duff, so I replaced that, along with the pickup coils. Still no joy. They say they checked the other relevant switches.

I've checked the coil and even swapped out with another CDi to cure the problem. The bike now starts on the kickstart with the swapped CDi, but not via the starter (starter whirrs but there's no spark). It also runs unevenly when revved a little.

Any inspiration anyone? This is driving me - and the Yamaha mechanic - crazy, and after 8 years of reliable ownership somewhat denting my faith in the bike.

Any ideas welcome.



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Super Guru

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Sounds like a bummer

I take it you have checked the splines on the starter motor pinion? and all the other starting gears?



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Thanks. The starter turns the motor over, but there's no spark. It's had a recent sprag clutch replacement anyway.

I can only think that the electrical power is somehow draining. Earths and regulator have been checked.



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Have you checked the woodruff key?



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Super Guru

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https://ttr250.activeboard.com/t43817790/woodruff-key/



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No, I haven't. Why would that create a sudden onset of no spark - can things move or change?



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Super Guru

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If the woodruff key in the flywheel has sheared, the flywheel position on the crankshaft can change, which affects the timing of the spark, but given that kick starting the ttr is often quite hard, the fact you can start it on the kicker suggests the timing is not the problem.

I have a Husky TE610e which would spin over on the starter quite happily but not fire, but when I attached jump leads she'd fire up straight away. Turned out the battery was not up to it - the starter motor was taking so much juice there wasn't enough voltage for the cdi to trigger a spark. The Motobatt now keeps the workshop door from closing in the breeze and a Yuasa starts the Husky! You might find your starter is dragging the battery voltage down too low, but when you kick, there's no drain on the battery so away she goes.

Can't answer for the poor running, but you may have a fouled plug from all the cranking with no spark.

Try jump leads or a new battery.

Good luck.


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Thanks, Super Guru. I'll try swapping out a battery or using a power pack to see if my Motobatt is a potential door stop too....



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Well, that took a while to sort out.

Having examined and cleaned all the electrical connections, I took a deep breath and ordered a new Yamaha stator from Fowlers - putting aside the (much cheaper) Chinese one from Amazon. Although the old Motobatt battery was putting out a resting 12.6v, its output was woeful when tested while the starter was pressed. A new battery has solved the issue. Bikes runs better with a quality stator in it too.

I now have a Chinese stator and a Motobatt as door stops.....



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glebe74 wrote:

Well, that took a while to sort out.

Having examined and cleaned all the electrical connections, I took a deep breath and ordered a new Yamaha stator from Fowlers - putting aside the (much cheaper) Chinese one from Amazon. Although the old Motobatt battery was putting out a resting 12.6v, its output was woeful when tested while the starter was pressed. A new battery has solved the issue. Bikes runs better with a quality stator in it too.

I now have a Chinese stator and a Motobatt as door stops.....


Lessons learnt! Glad you got it sortedsmile



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Super Guru

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Wrap some holly round the stator for an attractive christmas wreath

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