2001 TTR250 possible CDI issues...

First off I'm new here, so I apologize if this is a regular subject, but I've done a fair bit of research and can't seem to find much on the subject so my guess is, is that it's fairly rare. Secondly, any helpful insight you guys might have would be very much appreciated.


So lately my TTR250 has been playing up.

When it gets hot (After a good two hours of fairly hard riding) for some reason the starter motor wants to keep cranking over and the only way to stop it is by pulling out the battery. Turning off the key does nothing and neither does hitting the kill switch. When this first happened my horn also stayed on so I unplugged it and haven't used it since. 

It only happens when I press the E-start though, I can kick it over no worries and it will run fine.

I've replaced the starter solenoid, checked all the wiring, cleaned all the earth's, I've even had to replace the battery a few times due to it being fried by the starter motor.


A mate of mine seems to think I picked up a faulty starter solenoid and that when the bike heats up the solenoid is staying closed which would cause the starter motor to have a constant power source and to keep cranking. I on the other hand think that my CDI may be on the blink. I've read that they occasionally play up when the bike gets hot and then when the bike is cool again they work fine, which is exactly what is happening... If I get the battery out in time i can chuck it back in again once the bike has completely cooled down, and it's right as rain.


Admittedly I have yet to pull the starter motor out and check it, but to me it doesn't seem top be the issue.


I guess what I'm trying to get at is, has anyone ever had their starter motor constantly crank over and had no way of stopping it, aside from quickly pulling out the battery? If so what caused it?

Assuming this is like my TT-R230, in order to energize the starter solenoid, the main switch has to be ON, the start switch has to be closed and either the neutral switch or the clutch switch has to be closed.  I don't see how the CDI would come into play except that it would kill the motor if the kill switch were acting up.  It doesn't look like a bad CDI would affect the starter.


Since power is always applied to the solenoid when the main switch is closed, all it would take is a short in the solenoid to turn the starter.  This could be either a short to ground on the coil or the contactor shorting.


You could disconnect a solenoid coil wire (make sure not to short it to ground) and get the bike hot.  This is no different than having any of the downstream switches open.Then see if the starter wants to engage.  If it does, the short is across the contactor.  If not, check the continuity across the solenoid terminals. If you have continuity there, then the solenoid coil is shorting. 


Get the manual so you have the wiring diagram.  Your TT-R250 circuit could be different. But, once you see what's in the circuit, you can isolate the problem correctly.

Im pretty sure its your stator/exciter coil in your magneto pretty rare for your cdi to go mate

That is the classic symptoms of a short to earth someplace in the wiring harness. The CDI does not control the horn or the starter motor. You need to trace your wiring loom paying attention to places it can rub like under the back fender, where it passes under the seat and tank. Start at the battery negative and work forward. If worst comes to worst i have a spare wiring harness from a 1999 TTR 250 kicking around. Good luck and thank god it’s not your stator as there much more expensive.

I have the same problem with my Yamaha ttr250 2007 how was this resolved?


According the the manual this should almost be impossible to happen but yet I have had it happen twice, the starter, stated on its own and  kept turning even with the ignition off

even after the starter solinoid and start switch had been checked,  the starter solinoid replaced and the orignal one verified not faulty, it happened again yesterday??

Edited by bcmalloy

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