There was a post some time ago about replacing the pinion shaft in a TTR250 starter motor rotor with one out of a FZ600. Could you tell me what year FZ600 or doesn't it matter.
If you look at this link below (it from the Dirty Biking Features archive), it shows a complete rebuild on the TTR starter. - A system which I developed and it works very successfully.
I just went into a local bike breaker and matched up a starter with the correct teeth and length of shaft to the starter face - it just happened to be a fz600 (others may also do, but I can not guarantee it). The rear of the FZ shaft has to be shortened after the armature has been removed.
I hope you find the diagrams and copy helpful - Best wishes.
Interesting article, thanks for the detail! I think most automotive Engineer people (SAE) call the teeth on the armature shaft, both in the field and where it engages a gear, a SPLINE. Gears rotate against other gears. Complete aftermatket starters can be bought on ebay (US) FOR ABOUT $81+ shipping. I don't see how a F600 starter with a different internal spline will engage a TTR-250 ARMATURE FIELD when (bashed) pressed together without ruining both parts.
Interesting article, thanks for the detail! I think most automotive Engineer people (SAE) call the teeth on the armature shaft, both in the field and where it engages a gear, a SPLINE. Gears rotate against other gears.
Hi Chaser welcome to the forum - just a few comments - on your comments...
On the starter armature shaft there are splines and gears. In the UK motor industry most people refer to gears having teeth - at least that is what is written in all the official engineering hanbooks that I have had to read.
Complete aftermatket starters can be bought on ebay (US) FOR ABOUT $81+ shipping.
When this article was written - 2005, the only other option was a £360 starter, there were no cheap imports available.
I don't see how a F600 starter with a different internal spline will engage a TTR-250 ARMATURE FIELD when (bashed) pressed together without ruining both parts.
You would be correct, but your assumption is that these shaft splines fit into a splined armature. - They don't. All these starters are built to work with just an interference fit. The splines 'bite' into a totally smooth armature core. So the mismatch in splines is totally irrelevant in this case.
I only wish there had been cheap alternatives back in 2005.
