TTR250 Starter Motor Information

DISCLAIMER: The modifications described in the following text are for educational purposes only. In no way do I recommend that you apply these modifications to your own motorcycle. If you do choose to go ahead and modify your motorcycle based on the information in this document you will accept all responsibility for your own actions. The author(s) of this document, and host(s) providing it for you, accept no responsibility whatsoever. If you are unqualified to make any of the changes described herein but are bent on doing the modification, seek out a knowledgeable friend or professional mechanic for assistance.

 

TTR250 Starter Motor Information

 

NOTE: This is just a guide; it does not replace a service manual, general mechanical knowledge, specific motorcycle repair experience and good old common sense. With the proper tools, some general experience and this guide most users will be able to successfully service, replace or repair their starter motor . If you have any problems then stop and ask questions on the forum, take pictures of your point of confusion and get your answers before you start.

 

General information:

Replacement parts:

Case history:

A friend was having trouble with her TTR starter. It started as an intermittent fault and then it stopped working altogether. The switch was OK and there was a healthy click from the solenoid. A tap on the starter would get it turning over indicating a problem with the brushes or commutator. I took a few pics of the strip down in case it might help someone else.


It isn't possible to easily take the starter out from the LH side without removing the generator cover as the carb is in the way. So it comes out the RH side. 

 

Firstly take the Jubilee clips off the shock reservoir and park it out of the way. Then undo the three union bolts on the oil line being careful not to lose the washers or drop anything nasty into the oil holes. Once removed just pop the lower two bolts back in the holes to stop anything falling in.

Starter_removal 001.jpg

Next, remove the 10mm bolt that holds the clutch cable retainer in place and move it out the way.

Starter_removal 016.jpg

 

Once removed there is plenty of room to get the starter out.

 

Positive terminal - feed from solenoid. Lift rubber cap and take off the 10mm nut that holds the terminal on.  I have thinned down a 10mm open-ended spanner on a grinding wheel to hold the nut under the cable end to stop it turning.

Starter_removal 016.jpg

 

Starter_removal 016.jpg

 

The starter can sometimes be reluctant to pull out so a bit of gentle persuasion at the generator cover end helps.

Starter_removal 017.jpg

 

It is difficult to write down exactly how to extract the starter but it's basically a case of rotating it whilst wiggling it out - no force needed!

To get it past the timing chain tensioner I recall it needing to be upside down!

Starter_removal 020.jpg

 

Before stripping down the starter make sure there are some marks on the body so that it all goes back together the right way. Having put a body back the wrong way around once before (it makes the starter run backwards!) I now put two scribe marks on one side and a single on the other.

Starter_removal 004.jpg

 

Sure enough one of the brushes was stuck.

Starter_removal 005.jpg

 

The other side of the brush set!

Starter_removal 006.jpg

 

I cleaned the offending brush up with a bit of emery and it now moves freely.

Starter_removal 008.jpg

 

If the washers on the live feed terminal of the starter have been disturbed then this is how they should go back on:

 

Starter_removal 008.jpg

 

In real life they should look like this with the big fibre washer directly under the nut with the two smaller ones below it. The large fibre washer provides a lip that the rubber boot cover snaps onto to cover the terminal and top nut.

Starter_removal 008.jpg

 

The starter motor all back together and ready to fit!

Starter_removal 008.jpg

 

To prevent oil leaks from the oil feed pipe, I annealed the copper washers (heat to cherry red for a few minutes and then quench them in cold water) before putting everything back together again.

Starter_removal 009.jpg

 

The starter was new not long ago but I am guessing limited use and storing the bike outside under a cover may have contributed to a bit of corrosion building up. Anyways up, all working fine now!

 

Brian Sussex

Compiled by Brian Sussex, Devon, UK

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