I have a ttr250 raid. Just purchased for field use, starter gear worn and removed needs replacing.and no battery any how i thought it would be easy enough to bump start however it takes a tow at 20mph to start.even when warm cuts out same again need tow. Should it bump start easily new plug maybe ?

1. Disconnect the cable from the negative terminal of the battery.

Fig. Exploded view of the starter motor mounting - 5S-FE engine shown, others similar (click image for zoom)

1. On some early models with cruise control, you may have to remove the battery.
2. Also on some models with cruise control, remove the actuator cover and disconnect the wiring harness. Remove the three bolts and then lift out the cruise control actuator. Remove the bracket from beneath the actuator and put aside.
3. Peel the rubber boot away and remove the nut and disconnect the negative battery cable from the magnetic switch terminal on the starter. Disconnect the electrical connector also located on the magnetic switch.
4. Support the starter by hand and remove the two mounting bolts.
5. Remove the starter from the transaxle.

1. Place the starter motor in the transaxle and support by hand.
   
2. Install the two mounting bolts and tighten them to 29-31 ft. lbs. (39-42 Nm).
   
3. Connect the connector to the magnetic switch. Place the battery cable on the switch terminal and install the nut. Tighten the nut and position the rubber boot over the cable.
   
4. Using the ignition switch, "bump" the starter over a few times and check for proper operation.

1. Remove the starter from the car. Remove the heat insulator from the starter assembly, if equipped.
   
2. Disconnect the wire lead from the magnetic switch terminal.
   
3. Remove the two long, through bolts holding the field frame to the magnetic switch. Pull out the field frame with the armature from the magnetic switch.
   
4. On 1.0 kW starters, remove the felt seal. On 1.4 kW starters, remove the O-ring.
   
5. To remove the starter housing from the magnetic switch assembly:
   
1. On 1.0 kW starters, remove the two screws and the starter housing with the idler gear and clutch assembly.
   
2. On 1.4 kW units, remove the two screws and the starter housing with the pinion gear, idler and clutch assembly.

1. If necessary, install the gears and clutch assembly to the starter housing. Apply grease to the gear and clutch assemblies and:
   
1. On 1.0 kW starters, place the clutch assembly, idler gear and bearing in the starter housing.
   
2. On 1.4 kW starters, place the clutch assembly, idler gear, bearing and pinion gear in the starter housing.


2. Insert the spring into the clutch shaft hole and place the starter housing onto the magnetic switch. Install the two screws.
3. On 1.0 kW units, install the felt seal on the armature shaft. On 1.4 kW units, install the O-ring on the field frame.
   
4. Install the field frame with the armature onto the magnetic switch assembly and install the two through bolts.

1. Connect the wire to the terminal on the magnetic switch. Install the heat insulator, if equipped.
   
2. Reinstall the starter on the vehicle. Check starter system for proper operation.

Dead...? Sticky solenoid due to corrosion or glued up lubricant and dirt ? dismantle and rub clean with some emery paper. Worn starter motor armature brushes ? strike motor body with end of a piece of timber whilst cranking; the jolt may encourage enough contact to get the starter motor running for long enough for ignition to occur. ? For a permanent fix dismantle the starter motor and replace the carbon brushes. Corrosion in the starter motor body between the steel jacket and aluminium gear casting.? insert self tapping screw between the two parts to bridge the corrosion? For a permanent fix remove motor and strip down and wire brush components back to the metal and then reassemble.

Click, click, click ...occasional start Worn contact plates in solenoid failing to provide high current to energize the starter motor windings? dismantle solenoid and replace copper contact plates and plunger ring (readily available as an inexpensive overhaul kit).

Wahr, wahr, warh...laboured motor Worn bronze bearings on the ends of the starter motor are allowing the armature to run off centre and grind against the surrounding field magnets on the inside of the motor body? dismantle motor and replace the bronze bearings (inexpensive fix). Over-drawing motor - high current is drawn but this is not translated into effective turning effort by the motor. The field magnet windings have begun to short out, probably as a result of age or through over use in constantly trying to start a poorly igniting engine ? replace/ exchange the starter motor as the field windings of the stator magnets on the motor body are fried and beyond repair. Wheeeeeeee ..no start Although engaged fully with the flywheel a slipping pinion gear clutch means that the motor is ineffectual at turning the engine over ? remove the starter motor and replace the pinion gear on the end of the starter motor shaft

Lottery start...occasional no start

• The motor occasionally refuses to turn first time and has a defined rhythmic pulse when turning over - this is due to either burnt out armature coil or the contact face of the armature has become badly pitted causing the brush to miss making contact.

? - replace/ exchange the starter motor as armature windings are beyond repair.

1. Disconnect the negative battery cable from the battery.
2. Raise and safely support the vehicle.
3. If equipped with 4WD, remove the front driveshaft.
4. Remove the nut and disconnect the starter wire.

1. Disconnect the starter connector.

1. Remove the bolt holding the starter stay to the upper stiffener plate.
2. If equipped with 2WD, remove the starter by removing the nut and three bolts.
3. If equipped with 4WD, remove the starter by removing the nut, four bolts, and the center bracket.

1. If equipped with 4WD, install the starter, the center support bracket, nut, and the four bolts. Tighten the bolts as follows:
   • Bolt A to 41 ft. lbs. (56 Nm)
   • Bolt B to 30 ft. lbs. (41 Nm)

1. If equipped with 2WD, install the starter, nut and three bolts. Tighten the bolts as follows:
   • Bolt A to 41 ft. lbs. (56 Nm)
   • Bolt B to 30 ft. lbs. (41 Nm)

1. Install the bolt to hold the starter stay to the upper stiffener plate. Tighten the bolt to 43 inch lbs. (5 Nm).
2. Install the starter connector.
3. Connect the starter wire with the nut. Tighten the nut to 78 inch lbs. (9 Nm).
4. If equipped with 4WD, install the front driveshaft.
5. Connect the negative battery cable.

1. Remove the starter from the van. Remove the heat insulator from the starter assembly, if equipped.
2. Disconnect the wire lead from the magnetic switch terminal.
3. Remove the two long, through bolts holding the field frame to the magnetic switch. Pull out the field frame with the armature from the magnetic switch.
4. Toseparate the starter housing from the magnetic switch assembly, remove the two screws and the starter housing with the pinion gear (1.6 kW), idler and clutch assembly.

1. If necessary, install the gears and clutch assembly to the starter housing. Apply grease to the gear and clutch assemblies and place the clutch assembly, idler gear, bearing and pinion gear (1.6 kW) in the starter housing.
2. Insert the spring into the clutch shaft hole and place the starter housing onto the magnetic switch. Install the two screws.
3. Install the field frame with the armature onto the magnetic switch assembly and install the two through bolts. Tighten the bolts on the 1.4 kW to 52 inch lbs. (6 Nm) and on the 1.6 kW to 82 inch lbs. (9 Nm).

1. Connect the wire to the terminal on the magnetic switch and tighten the nut to 52 inch lbs. (6 Nm). Install the heat insulator, if equipped.
2. Reinstall the starter on the vehicle. Check starter system for proper operation.