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Street legal a TT-R 250 - dual sport conversion
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So I'm not even going to attempt to do as well as Brian's Superb posting on modernising the TTR, but I just want to have a bit of fun here.

The object of my affection, to take my 2006 TTR 250, make it legal for road use here in Connecticut (which is NOT the easiest thing in the world) I work about 10 miles from home, so when its nice I want to commute on "Bluefish" (my son's nickname) and ride at weekends. I'm originally from London, and I have to tell you living in New England is a stunning place to live - and ride!

So the starting point..........

IMG_4505.JPG

 

Thanks truslack, Regarding the Baja kit.....Ive seen it, I think its a bit expensive for whats in the box........   So far I got a handlebar switch horn/ lights high /low + turn signals from ebay for $11.00,

$(KGrHqQOKpEE3uRTcL!LBOCPuVMUbw~~_12.jpg

 Im making my own tail pipe from a wr250 pipe -details to follow (because the tail pipe bafle was cut out)

$(KGrHqJ,!g4E7P9OcI2TBO6-!tvL1w~~60_3.jpg

 a Yammy SX 250 speedo for $31.00 (ebay)

speedo.jpg

yes the one on the left! I'm going to remove it and fabricate some mounting brackets. Most of the N/A spec TTR's Ive seen only have an odometer no 

I want to get some flush mount turn signals from ebay and I am looking for an XT 225 headlamp assembly - anyone got a line on one?  I'll need a chain guard and a horn also because of Connecticut laws......  I'm open to suggestions for those too people!!. Just got a skid plate which I think will fit too!

20111012-103004.jpg

hmmmm

 

Got 2 DOT approved tires from ebay also $48.00 the pair + shipping.

So the mechanical stuff... I'm on a tight budget (who Isnt these days?) But I used to be a motor cycle mechanic in London as a teenager, So I figured I can work on this....get something and keep the dollars down.... I started out at $1600 for a very low use 2006 I found in Brooklyn, New York. The guy had bought the bike in 07 ( showed me pics) from the original owner, and had ridden it 6 times - I asked " 6 times a year?" no he said "6 times in total" I went down to get in the car..... phone rings........

I cant get it started...... let me take a look and get back at you.....

radio silence for 4 days......

Oh well I'll start looking for another....

That night the phone rings..."Hi its me - I got it running, but its hard to start and the header glows. Look, I am at college, I dont have time to work on it, if you are still interested I'll work something out - I need money for school so if you want to fix it you can take it as is for less......"

"How much less?" I asked...

"How about $1000"

I drive to Crooklyn.... is this a pig or is it real? I'm thinking on the way......

I check it out - he's not a B.S'er, he's a nice kid - "if you cant fix it, I'll give you your money back" he says as I eyeball it and take in the details... I use the "what to look for" guide, (Thanks again Brian!!)  I look it over.... brake pads almost new, chain never adjusted, holy canolli this IS a DEAL!!!!

Took it home, downloaded the shop manual, cleaned the carb - the screw under the carb was almost all the way out!!!, spark plug looked like it was dipped in tar...

New spark plug, gapped correctly.... fired it up, different bike - set the screw at 1.5 turns out from closed, rode around.. maybe 3 miles all together.... but its still not right.... mad idling- around 1800 +/- header glows sometimes, others it doesnt....

CARB TIME - this time, I rip the carb to bits.... soak everything in Acetone then going over the jets.... cant see through one.... I get my welding tip cleaners out (every owner should have one in their tool kit) I clean every orifice out, its obvious the bike has never been drained over the winter....put it all back together, put an ounce of Acetone in with a gallon of fresh gas, fire it up...... get it warm..... turn the screw under the carb out to 2 1/4 turns.... BINGO!!! then crank the idle screw for the throttle cable out, now it idles around 700 like a swiss watch. Ride it somemore .... Im falling in love now!!!!!! As Shakespeare said...."Be still my beating heart"

final thought - Ive read quite a bit on various different web pages etc - its not a mystery, Dont be scared of the carb, its a very simple, easy to sort out piece of hardware!, even a novice can pull it, clean it, tune it.

 

 

more to follow folks....

have a nice weekend!

 

Matt

 

So moving along, I needed to find a Chain Guard (requirement in Connecticut)  couldnt find one in Europe, NA versions didnt have one.... So back to ebay... a score!  XT 225 chain guard and a horn for $22.00 including shipping.

xt225 chain guard.jpg
Sometimes goodies come along that should be in the mix...... Got these from a forum member, lets just say mine were well...... "past the sell by date" so Im waiting for these to arrive....

PlasticsA.jpg

 I'll be converting the headlamp to high/low beam......  (Thanks Larry!)

Next Im going to try and pin down some turn signals.... looking for something small and flush.... any suggestions fellow ttr's?

 



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Matteo

I'd give my right arm to be ambidextrous...



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Making a 2006 TTR road legal
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I know it's quite expensive, but Baja do a kit http://www.bajadesigns.com/ProductDetail/121014_Dual-Sport-Kit-Ttr250



-- Edited by truslack on Friday 10th of February 2012 03:03:26 PM

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Hi, Matt.

I put a speedometer cluster from an xt225 on my NA TT-R250 with very little hassle--no cutting or other modifications to the speedometer cluster required. I also agree with truslack that the Baja kit might be worth the price, in the end--especially considering the great deal that you got on the bike.

Is that an xt 225 bash plate that you are considering putting on the TT-R? Is it a plausible fit? I don't really like any of the after market plates that I have seen being sold for the TT-R250 here in North America, and I have been considering having a very simple one fabricated that could fit between the stock protection bars and the frame.

Larry

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Hi Larry, thanks for your comments I was looking for XT speedos as well but couldnt find one. Im only going to use the speedo not the whole cluster, As soon as I recieve the XT bash plate I will let you know how plausable it is.

Regards,

Matt

PS love your motto - my life has been WAY to full of serious, Im finding time to play again!!

 

PPS did you make yours road legal? what did you use?



-- Edited by matteo on Monday 13th of February 2012 04:22:16 AM

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I'd give my right arm to be ambidextrous...

LRJ


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Unfortunately, in California, since 2003, one can no longer make dirt bikes street legal.  Fortunately, I found this bike that someone else had made street legal in 2001. (Estimated to have less than 2,000 mi when I bought it.)  The previous owner had purchased a Baja kit to this end.  Their kits seem to have been oriented to meeting California's requirements for being street legal: turn signals, headlamp with bright and dim switch, brights indicator, horn, and license plate illumination.  Except for the last piece, everything works very well and fits the bike well.  A speedometer is not required to be street legal in CA, so one is not included in the kit.  I like to have an objective gauge of how fast I am going, so that was my first modification after I bought the bike this last November.

I plan to use it primarily for off-road, but that includes forest service roads, and licenses are required to ride on those.  It is also good to be able to use public streets to go to trails or to connect trails.  I have an xt225 for commuting to work and riding around town, but I like riding the TTR even more--even on streets.biggrin

Good luck with your project, Matt.

Larry

PS:  I am very interested to hear how you were able to make the xt plate work.  Again, good luck.



-- Edited by LRJ on Tuesday 14th of February 2012 05:09:16 AM

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Pete if you need help you can e-mail me mfairy@optonline.net or skype and I can walk you through it. Do you by any chance have access to a set of welding nozzle cleaners? I bought mine for about a tenner - the needle sized cleaners are for cleaning the tips of accetylene torches, they are THE BEST tool you can ever have for cleaning out holes in the jets. Also when you strip it soak EVERYTHING overnight in acetone. It will clean all the crud off. If you are scared, take pics as you dissamble it - then you have a reference.
Let me know if you need any help mate!

Matt

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Matteo

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Hi Matt -

I'd be very interested to hear if you have success with your effort to make the bike road legal.  I've recently done a great deal of research on the issue of titling and registering a dirtbike (that wasn't offered in U.S street legal form by the mfg), and from what I've learned, there are very few U.S. states left (if any) where you can still get it done.  The problem is that in order to get it registered, the state does a lookup of the VIN. The VIN has a code that indicates whether the bike was delivered to market with the appropriate EPA/FMVSS emissions and other approvals.  See here for a detailed discussion of the issue.

I have a U.S.-spec TT-R250 ('04) and CRF-250X ('05), either of which I'd love to make street legal (the CRF already has the full Baja kit installed).  But both bikes have the "off-road use only" stickers that indicate that most if not all state DMV's will refuse to issue a plate based on the VIN codes.

I live in DC, but my folks live in CT, so if you figure out a way to do this in CT I'll haul my bike up there and plate it in CT using my folks address.

Let us know how you make out.

Dave

Washington, DC



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Street legal a TT-R 250
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Making a 2006 road legal part II - $2.00 per cc………..

So I’ve always been the bloke that the lost or stray dog followed home……  I believe the technical term is sucker!!! (My faithful mutt Winston is sitting with me as I write this)

IMG955900.jpg

As soon as I figure out how to get this in one post, with people’s comments in sequence - I’ll put it all in one post!  As you know from the first piece, I’ve been collecting up bits here and there. ( Thanks Larry for the beautiful headlamp and fender)!!! My search is narrowing down, I’ve almost got all the parts.  I had gotten a good deal on a set of almost new DOT legal tires, and I wanted to find a pair of rims to put them on. I was seeing rear wheels for $250 even 275! And front wheels between $ 175-225 – YIKES! This is not cheap!hmm

So I kept searching the web, looking for TTR250 and found an 02 with a blown motor for $500.

ttr.jpg

He had misspelled Yamaha (spelling isn’t my strong point either) So after I looked through the add it had been posted 4 times (120 days) I’m not sure why but I called the guy, thought I would ask him if he wanted to sell the wheels. As we spoke He assured me it wasn’t stolen and I just blurted out “I’ll give you $250.00” to my surprise he said yes!

 

This is what it looked like, and I got my wheels…..

IMG_4715.JPG

IMG_4716.JPG

I got it home, and began to pull it down. Bit of frame damage, OK TTR's how should I fix that? suggestions please..... I  also want to tear that motor down and see what the score is. ( noone day)

IMG_4718.JPG

 scruffy but nearly all there........

IMG_4719.JPG

 IMG_4722.JPG

Later that day…..

I get an e-mail from my autosearch - I think this is a message to me……..

For Sale TTR 250 engine. Less than 10 hours, Got it for a go kart project which never happened.

ttr engine.jpg

I called the guy,  turns out the bike was brand new, He went riding with his brother in law CR 250 and TTR 250 , VERY first ride, he got it sideways and hit a tree, bent the frame and swing arm, broke his leg and that was that. His brother in law parted the bike out and gave up riding…….

It was advertised for $350 and for the second time that day I offered $250 and he said yes….oh well

Now we are at the magic $2.00 per cc!

So the plan is, get my bike road legal, then put together a second bike for friends ( maybe one of my son's) to ride.... we'll seeblankstare

Matt



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Matteo

I'd give my right arm to be ambidextrous...



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RE: Making a 2006 TTR road legal - part II $2.00 per cc........
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Give us all a clue, Matt. confuse

What, specifically, is it that you call "frame damage"?

Looking at the photos it is very hard to discern anything wrong.  doh

If you can give a shot of the damage and describe what we should be looking for then we may be able to offer suggestions.

The bike looks to be missing a seat, side panel and the frame protector is dangling at the front - other than that ?????? confuseconfuseconfuseconfuse

Martyn

 



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close up of the frame damage:

ttr frame ouch.jpgso the mounting bracket lug at the rear on the "hoop" end is about 1" off center, and one side is lower by about an 1 1/8th"

To answer your question clubber, the bits missing are battery box, r/h side panel, rear mudguard & light.... its basically all there.

 

So please guys give me your thoughts on fixing the bumper,

 

Matt



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Matteo

I'd give my right arm to be ambidextrous...



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I reckon the tab is in the right place - see pic below with 3 examples:

frame tabs.jpg

With a bit of "technical" assistance it is possible to bend the rear subframe straight.

Brian



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Brian :

Hi Brian, I tried a line up with a rear mudguard - its off as described....... The tab IS in the right place the hoop of the frame is not!no

Pete, switching an engine is MUCH easier than rebuilding one!  After rebuilding an E-type engine, nothing is that difficult anymore.......

but thanks for the salute!  Pete what tires are you using mate? are they road legal?

 

Matt



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Matteo

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Brain Flash..... Brian I get what you mean, sorry I didnt explain clearly I know the mounting bracket that connects to the rear mudguard is in the right place, what I meant was the hoop isnt! if you look at the piccy 3 below winston rear view of the bike , you can see the l/h frame rail is quite a bit higher than the right side.....Do you see what I mean?
over to you ,


Matt

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Matteo

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I am betting that it will bend to the correct shape with a decent length of 4"x2" used as a lever.



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Brian, should I heat with a torch before bending?

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Matteo

I'd give my right arm to be ambidextrous...



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matteo wrote:

Brian, should I heat with a torch before bending?


Try without but if it isn't bending as you want then apply some heat where you want it to bend - but I would advise two of you on that job. 



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making my 2005 TTR street legal in Utah?
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It has a horn, headlight, brake light, front and rear brake light switches, review mirror and a plate holder.  What else do I need?



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LRJ


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How you tried contacting the DMV in Utah? I think that is your best bet, as each state is very different and the regulations do change over the years. What you want to do can't even be done in CA, anymore.

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Bike is licensed in Utah, had to have all the above, plus DOT tires, speedo and turn signals

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Making a 2006 TTR road legal - part II $2.00 per cc........
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Its Exhausting.........no  Poor mans Powercore

So noise was an issue, my old pipe came with no baffle,

IMG_4523.JPG

 I was offered one for $50, thats not happening and it wont pass inspection as is.(too noisy) SOooooo  I finshed up with this....

$(KGrHqJ,!g4E7P9OcI2TBO6-!tvL1w~~60_3.jpg

A 2 hour WR250 pipe - very cheap. I finally finished work early enough to get something done..... off with the old one, and on with the new one.

 

I started trying it for size, it was much longer and stuck out way too far, so out with the hacksaw......

IMG_4528.JPG

and a little cut and trim .......

IMG_4537.JPG

so I can weld the end piece back on like this..... and then trial fit again.

IMG_4764.JPG

all good so far and trim off a wee bit more ........ cut a pair of slits for the clamp.....

IMG_4769.JPG

and lets try it again.....

IMG_4766.JPG

except the brackets dont line up, I dont want to mess about welding onto the frame, so option B (Tidier) is move the bracket.... out comes Mr. Dremmel......

IMG_4807.JPG

later that Dremmel........

 IMG_4808.JPG

a bit of clean up so it sits nice and flat.......

IMG_4812.JPG

bracket needs to move a bit further back, and slightly sideways.........

 IMG_4809.JPG

new position vs old position.........

IMG_4811.JPG

Drill some holes ( I used AN6 aircraft rivets - very strong+ I had themno)

 IMG_4815.JPG

then in the body of the muffler

IMG_4816.JPG

and now........

 IMG_4817.JPG

time for a final try and fit.......

IMG_4819.JPG

zip it all back up........

IMG_4821.JPG

then we are ready for a little testing....... Ok so it looks pretty, its MUCH lighter, nice bark when it starts up....

SO a quick ride tells me it works too! more powerful, definatley more bottom end, and quicker throttle response. best of all its quieter than the stock pipe with the missing baffle. I already went to the WR forum ,and looked up baffle mods and/or removal for even more grunt. I'm VERY happy best of all I spent $65.00 all together.

Oh and yes the eagle eyed will notice no exhaust clamp - old one is welded on, and local autoparts shop is closed for the day.

 

I'll keep you posted, have a nice weekend guys!

Friday 6pm glass of wine time..... job completed!

I got another WR exhaust if anyone is interested.....

 

 

 



-- Edited by matteo on Friday 20th of April 2012 11:01:16 PM



-- Edited by matteo on Friday 20th of April 2012 11:06:46 PM

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Matteo

I'd give my right arm to be ambidextrous...



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Thats fantastic! I'd look at a wr250 pipe if mine ever got damaged or fell to bits. Having followed my mate on his wr250r all over the place I can testify to it sounding like a spitfire in a dogfight :)

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'54 plate Suzuki GSF 650S (Bandit)

Previously Yamaha YBR125, Yamaha TY125, Yamaha TY250



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Nice bit of engineering Matt - good job wink



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RE: Making a 2006 TTR road legal
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Dave it seems making the 250TTR road legal in CT is doable! contact me if you want more details......

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Matteo

I'd give my right arm to be ambidextrous...



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Carbs do need a bit of sttention if the bike has been stood for a while, makes the world of differnence, I find the float vlave has a tendancy to stick if it has sat for a while.

Out of interest does the xt225 bash plate go straight on? I have both a ttr and an xt and the bashplates look very different at a glance.


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no I have to modify the bash plate to fit.....I'm moving slowly I want to get it right.

Matt

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Making a 2006 TTR road legal - part II $2.00 per cc........
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So it just occured to me last night I may be boring some of you to tears, but to my English brothers, if its boring I apologise - WE DONT HAVE road legal TTR's here, there are a few that people have done and a couple of companies that did it when they were still available. So all you TTR fans overseas that ride everyday on the road - feel good about it - freedom!

I really have fallen for this bike, I love riding it, its one of - if not the best bike I have ever had! I've had some that were too fast, some that did'nt handle well, some that didnt stop well - I feel very good overall about this one!, and its mine!! I cant wait to get the work finished , get it inspected and get it registered.

So I have almost have all the parts now, I'll do a total up $$ when I have it and post here, but I know I spent WAY under the cost of a in-the-box enduro kit, and like most of you - I like to add bits that I think make it a bit more personalised.

My last and very good score is below $30+ shipping from a brand new WR250 on "fleabay"

$(KGrHqFHJCEE92I-jrZOBPmd1!(4L!~~60_3.jpg

I'll need a hydraulic brake light switch (anyone know what size thread it is?)

and I think thats it.

In Connecticut state law to register a bike states the motorcycle must have a DOT approved muffler (90-93db) so no FMF pipes!! speedo, front and rear turn signals, horn, mirror on each side, license plate holder facing rear, brake light front and rear activated, reflector facing rear, DOT approved tires, chain guard, hi and low beam headlamp.

I have to get it in a van or truck, drive it 80 miles to the test center, have it inspected and tested, ($80 fee) get a title ($20 fee) then register it (about 6% of purchase price) is it worth it? YOU BETCHA!! smile

Someone let me ride a WR250 for an afternoon, I'm not old by any means, but I was BEAT afterwards - the seat is a plank! Dont get me wrong if you own one - enjoy but the TTR250 is for me!

I'm really looking forward to this........

IMG_4829.JPG

Its my friend Larry's bike, XT250 and we have some stunning country lanes and green lanes around here, with some added approved forest trails.... I'm really pumped!

well ok Ive already done a few miles with him!

 

more soon,

 

Matt

PS stuck this in too......

gytr II stage.jpg

The difference is very impressive, and my old filter was clean!! + it was $20!! NOS.

Oh I found this today, a picture of my very first bike.....

03_82_50_s6m.jpg

anyone remember these? I used to proudly ride it around Walthamstow and the streets of the East end of London. life was simple then.... and it was a MOPED!!! you could pedal it by reversing the kickshaft, putting it in 6th gear and inducing an asthma attack trying to pedal.....

 

Matt


PPS suspension set up - what do you guys recoemnd for front and rear fork/ shock settings?


 



-- Edited by matteo on Friday 4th of May 2012 11:34:50 PM

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I used to ride a fantic twinshock that my mate had. Happy times, progress is all well and good but if I went back to it now it would be very limiting and the magic would have gone, which is a shame. Still, as long as I don't go back to one I can remember great fun on it



-- Edited by pedrosan on Saturday 5th of May 2012 09:54:56 PM

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Pete Brown

Keighley, West Yorkshire

'94 Yamaha TTR 250 Raid (with Open Enduro headlight, grrr...)

'54 plate Suzuki GSF 650S (Bandit)

Previously Yamaha YBR125, Yamaha TY125, Yamaha TY250



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Street legal a TT-R 250
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im looking to street legal my TT-R have looked at kits from oem to aftermarket. im wondering has any on the forum done a conversion and if so what kit would be the recommended, my TT-R is set up with a mile gauge so all i have to do is buy a speedometer so im ok there, just wondering about the lighting kits



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Isaacah, it's best if you tell us where you are because if I gave you the information to steet legalise your bike for UK it wouldn't be much use for you in USA. confuse

Even USA has different requirements for different states, so what are you after? confuseconfuse

Martyn



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See:

http://ttr250.activeboard.com/t47763949/making-a-2006-ttr-road-legal/

http://ttr250.activeboard.com/t48535220/making-my-2005-ttr-street-legal-in-utah/



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im just asking what if any aftermarket kit would be recommended if any one has really done a kit? the laws in Nevada are pretty straight forward heres the actual form from the dmv http://www.dmvnv.com/pdfforms/vp254.pdf  and from what most kits ive looked at the pretty much come with everything but the speedo.

those forums were very helpful thanks! i might have to look more into maybe building my own setup it might actually be cheaper.



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I used a Tusk kit for my lights blinkers and horn it all worked fine

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could you show me pictures of your bike with the kit on it? 



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Just got my inspection this AM, TTR is now totally legal; registered, insured & inspected!

Here in the US these things are completely up to the individual states & after reading all the stuff on-line it wasn't looking so hopeful, as many states have pretty resrtictive rules. But thankfully Vermont is one of the more reasonable places to deal with, so the process is complete.

I had to add: mirror, horn, brake light, low-beam, license plate bracket w/light & a speedo. Turn signals are not required here.

The brake light & hi/lo beam are already on the bike just not hooked up so switches were added & wired in. For the speedo, I got a Trail Tech Vapor, seems to work really well.

Now to start working on seat-time!



-- Edited by TDVT on Friday 20th of July 2012 11:16:18 PM

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Congratulations on your success.

You will now have to write the details as inspiration to others.

Pictures of the "new" street legal TTR will also be required. smile

Martyn



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Budleigh Salterton. Devon



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thumbsup.gif



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LRJ


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Congratulations! I wish that the process or making a dirt bike street legal was as reasonable in California.

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I recently got my TTR on the road here in Vermont & on Martyn's suggestion, thought I'd share what I ended up doing. Many other states have more requirements so your mileage may vary, as they say.

As I posted in another thread, I had to add: mirror, horn, brake light, low-beam, license plate bracket w/light & a speedo. Turn signals are not required here.


The first thing I sourced out was a light/turn/horn switch as most of my wiring would involve that part. Mateo had found a nice one on eBay & I bought the same unit, it cost me around $10 shipped.

140.jpg

It was MUCH cheaper than most you'll find & my only gripes are the small gauge 10” pigtail wires & that the bullet connectors are smaller than the standard Yamaha connectors. It would be really nice if it had heavier duty wiring but it works fine. It also has the turn-signal switch which I didn't need to use, but I have the option.

 


I wanted to use the typical motorcycle bullet connectors for all the wiring mods to make maintenance/connections easier but had a hard time finding bullet connectors here in the US. Then I came across this site, EASTERN BEAVER. It is run by a Canadian motorcyclist now living in Japan & has a great selection of high quality motorcycle connectors, relays, etc. My order arrived here in less than a week, no issues with customs & shipping was about the same as if I had ordered from within the US. I crimped the connectors but also soldered all of them as well, since my crimpers are marginal at best. There is lots of good info there about relays, etc.

 

For the mirror, I bought a BIKEMASTER folding mirror after reading a number of reviews. It folds out of the way nicely, doesn't vibrate too badly (it's actually usable) & the the regular right-hand thread version screws right into the hole on the clutch lever perch (mine had a plug in it). I did the left side only as that is all that was required. I think the TTR's right side has reverse threads, but they make a mirror for that side as well.

mirrorspeedoswitch.jpgfoldedmirrorcopy.jpg

 

The horn (in a lower pic) was a $10 generic 12V horn available from many suppliers. One place I found (but didn't order from, as I already had parts coming) was fourstrokesonly.com in California. He has horns, the brake switch I needed, license plate brackets & also a threaded block-off cap for the speedo drive. There is no online ordering, I guess you have to call. Lots of info there too.

 

The easiest way to wire in the brake light is to use a hydraulic actuated switch(s) (about $15). They take the place of the hollow bolt that goes through the banjo fitting on the master cylinders & close the circuit when pressure is applied to the hydraulic system. I wasn't required to have it on both front & back, so I have a switch on the back brakes only, as the wiring is more protected & tidy. From what I've read, a lot of states require front AND rear. The TTR uses the 10 X 1.25mm thread.

brakeswitch.jpg

 

The only lights the US TTR's have is the tail light & the high beam (only) wired to an on/off switch. I left the stock on/off light switch in place & fed my hi/lo switch (headlight section only) from that.

The light sockets are already wired for both low beam & brake light respectively, but there is no connection to the wiring harness for either. The proper dual-filament bulbs were already there on mine. I simply added a 1/4” female spade connector to the empty slot in the multi-connector (harness side) when I added the extra wires for the brake light & high beam. Due to the small gauge wire in the hi/lo switch, I decided to use a relay to provide power directly from the battery when I'm on the high beam. Eastern Beaver has a good info section on relay wiring.

minirelay.jpg

I also had to add a license bracket w/plate light & found some REALLY small LED illuminated license plate bolts on eBay. I decided to mount one above the plate instead of through the plate itself. Pretty bright, LOW current draw & it is tapped into the tail light for power. The aluminum bracket itself is fastened to the frame with countersunk bolts (w/rubber washers) into tapped holes.

platebracket-ledlight.jpg

In the time since I did mine, I have noticed many local hard-core enduro bikes have the plate bolted right to the fender, facing skyward. I think fourstrokesonly.com has a tail light lens that will fit a TTR & has a small strip of clear plastic at the base that would illuminate the plate in that configuration.

The horn & brake light are fed from a source that is switched on/off by the key (NOT the light switch) so they both always work when ever the key is on, even if the head/tail lights are off. If I were to have added turn signals, I would have used this same feed.

 

Last I added a speedometer, as the US bikes only have a trip-odo. I decided to use the Trail Tech Vapor after checking one out a local shop. Unfortunately the kit they had was for inverted-fork bikes (different sensor) like a WR. The kit that fits a TTR250 is #85-704, which I ordered directly from Trail Tech as no one had any.

I thought I could use the factory odo bracket to mount the Trail Tech (the included bracket didn't work either) but it was too low & I had to fabricate a new one to get a good line of sight, otherwise the installation was very easy.

speedobracket-horn.jpg

The speedo sensor adheres to the lower fork tube with some industrial double-faced tape & is activated by a magnet that takes the place of one of the brake disc bolts. They suggest wiring it directly to the battery (always powered) but it goes into sleep mode after 20 minutes of inactivity. As soon as the magnet passes the sensor it wakes up again, even pushing the bike around the garage.

speedosensor.jpg

It was also easy to calibrate. I used the rolling method where you mark the tire & floor, then roll the bike one front wheel revolution & measure the distance. That measurement (in mm) is the factor that you enter into the unit. The Trail Tech has many other functions; trip odo, accumulated mileage & time, time of day, air temp, etc. There is also an engine temp sensor but the wire wasn't long enough so I haven't hooked it up yet as I need to order an extension.

Bright display when hard-wired, no problem reading it in bright daylight.

In the end nothing really hard to do but luckily I had to make minimal additions,other states have more requirements; turn signals, chain guards, reflectors, etc.

I hope this helps with the basics, at least one way of doing it.

 


 



-- Edited by TDVT on Monday 23rd of July 2012 02:57:13 PM

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That is brilliant Ted, nice and detailed with good pictures.

I like how you've not destroyed or removed the stock TTR stuff and modified just enough to satisfy the rules.

I bet you're dead chuffed with it and well pleased. biggrin

Martyn



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Cubber wrote:

That is brilliant Ted, nice and detailed with good pictures.

I like how you've not destroyed or removed the stock TTR stuff and modified just enough to satisfy the rules.

I bet you're dead chuffed with it and well pleased. biggrin

Martyn


 +1

Excellent job wink



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Do you think you could help me out with wiring the two wires from the pressure switch? My TTR also has the double filament bulb already installed but i do not know how to connect it to the switch.



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Hello KamJam and welcome to the forum handshake.gif

The US TTR250 wiring harnesses do not have provisions for brake lights (according to the wiring diagram). You will need to splice a wire into the brown wire that leads from the ignition/main switch. This wire will then be a power feed wire for the switch. You now need another wire (preferably yellow) to run from the other side of the switch (the receiving side) to the brake light. The same must be done for the front (if required) but you should splice the two (preferably yellow) wires that lead from the switch to the brake light together, rather than have two wires to connect to the brake light.

yamaha-ttr250.jpg

Hope that helps, any questions- ask!

Jarrah



-- Edited by TT-R250M on Tuesday 7th of January 2014 11:02:20 PM

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Street legal a TT-R 250
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I have resurrected this thread in response to Jim's post and made it a "sticky".

I realise some of the information may be out of date so, if anyone can add or correct information on this thread, it would be very much appreciated!

Brian



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Does anyone know what year the WR250F pipe was from?



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