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Old 07-28-2015, 12:29 PM   #2
bull   bull is offline
 
Join Date: Feb 2015
Posts: 257
The way power flows in the two circuits is:

CONTROL: battery -->Ign Switch -->Brake Switch(es)-->Solenoid (primary coil winding)-->Start button --> ground

SLAVE:
battery-->Solenoid (internal switch)-->starter -->ground

Since removing the fuse, did not stop the cranking, then the control circuit is good. Thus the problem has to be in the slave circuit.

Most 250cc engines I have seen, crank what I consider an excessive time AND they pull enormous amounts of power at the same time. My guess is the solenoid gets overheated and corroded (most likely from condensation or rain). Or the starter is failing inside and pulling too much power.

IF I owned a 250cc, I would upgrade the solenoid and the cables. The solenoid I would use is a Ford suppression type. Yes, it would cost a few bucks, but the headaches would be over.
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