A forum for owners of Yamaha TTR250 trail and enduro bikes!

widge wrote:

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I hope you do not mind but having just picked up my bike (2003) I have a few maintenance questions.

1. The top exhaust thread is stripped so my local mechanic is going to helicoil it and ordered new studs from Brian.

2. The is oil leaking from the decompresser plug so ordered a new metal one from Brian.   

Tried to remove the toolbox side panel and the screw is seized solid so looks like it might need drilling out are those bolts just generic fairing bolts?

Removed the exhaust side panel and the heat shield stuff is falling off what can it be replaced with?

Is there something that covers the rear shock?  There is a black plastic cover that has two threaded holes in the bottom and then about 5 inches of spae exposing the bottom of the shock.

Where an I get a manual and parts list from as I would like to know the torque settings?

How often should the valves be checked every 12000 miles?

Rob

 

 

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 Hey Rob,

The M6 left side panel bolt is pretty common, click HERE for other model it is used on.

The rear shock has a mudflap that bolts to the airbox. It should be protecting the shock and fitted like this-

Valves should be checked every 1,200 miles (12,000 km) or every 12 months. This is a little excessive though unless riding off-road.

If you need a full repair manual, PM me your email address and I will send you a PDF copy. For a parts list just use the Partzilla site I left you, most parts will be the same as your country but bear in mind the TTR250 is an off-road machine in the US and slightly different for some things.

Any more questions, ask!

Enjoy!

Jarrah

Hi Rob

You have had some good replies already but I would like to add that I use radiator insulating foil on my RH side panel held on with spray glue. 

If you get stuck let me know and I can cut a piece to size and send it to you.

Cheers

Brian

Thanks Petenz.

That is what it looked like when I first rebuilt it, it has the usual wear now from offroad riding but still in good nick. I have recovered the seat recently as it needed doing. I was not all that happy with the sticker kit, I originally wanted a custom Unit or Metal Mulisha graphics kit but it fell through (the guy went to hospital). Would like to find a decent kit at some stage but for now I am happy.

The thing I like about rebuilding a bike yourself is that you get to personalize it, here is a few examples-

Enjoy!

Jarrah

p.s. hope you don't mind pictures Rob.

As advised in a PM Rob- if you want me to send the manual, I need your email address.

It is safe, just ask the 100 or so others I have sent it to.

Jarrah