I am the shop teacher for an intermediate school and we are rebuilding a 91 tb 250. I have replaced the piston and when i got every thing back togather it wont start. when I press the start button nothing happens. the starter wont even spin. i thought it might be the solenoid that is bad because i took a power cable and touched both posts on the solenoid and finally got the starter to spin. the dealership wants a pretty penny for a new solenoid so i went to autozone and bought one for 9.99. its off an old model ford but it is almost identical. when i hooked the new one up i had the same problem, nothing happened. i was thinking the start switch on the handle bar was bad. i checked the fuse on the wireing harness going back to the solenoid and it is good. does anyone have any suggestions or experience with one of these. any advice would be helpful that way i dont have to start ripping the thing apart and testing every thing. thanks.

 

battery good? do the lights work? if so bench test the starter and see if the starter is shot.

 

make sure the stop switch by the start switch is good to. they have a habit of getting dirty and not working without a good cleaning

 

I would try to get it started with the pull rope then mess with pulling the starter.The starters on these are in a bad place and get soaked with gas when the carb floods ruiing th e seals and gunking up the starter

 

thanks for the reply. the battery is new and charged. i hooked up the headlight but it didnt come on. its an old bulb and it could be burned out. when i hooked the solenoid up and hit the start button the starter wont even spin. i took a power cable and touched both posts on the solenoid basically bypassing the solenoid and the starter fires. when i got the 4 wheeler the pull start was missing so i cant even use that. the starter is missing one of the gears that meets up with the fly wheel so even if the starter spins from hitting the start button it still wouldnt start the motor. i just wanted to hook everything up and see if everything has power. i will go and get some contact cleaner and use it on the run and start switches and see if that helps. thanks for the reply

 

thanks for the reply. when i got the 4 wheeler who ever had it before me pulled the starter and it was full of oil. we pulled it apart and cleaned it. when we put it on a battery it worked fine. if i jump the posts on the solenoid with a power cable the starter fires. i may be a dirty switch. i appreciate any help from you. hit me back if anything else comes to mind.

 

i would check to make sure your getting power to everything. it sounds like the switch isnt sending power to the solenoid to start the motor. looks like you are just having a power problem somewhere. your gear that your missing is called a bendix drive. when it starts spinning a certain way, it throws another gear to the flywheel to spin the motor over. it rea

 

Drop me a pm if you need a recoil.