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

Padowan · Senior Member

Starter gear cover bolts made of cheese.

TTRfan · Super Guru

100% agree Simon - they are useless

Normally at least one of the original bolts has to be shifted with a hammer and cold chisel applied to the edge of the bolt head.

I always replace them with these - 6mm flanged bolts but with heads that take an 8mm socket rather than the usual 10mm so they look better wink

Brian

Mogwai · Senior Member

Had to get a seized one out today, as the guru says, knockometer and chisel/sturdy screwdriver method is best. Cut a nice slot somewhere on the head and give it a few tw@s, jobsagoodun.

Goalkeeper · Senior Member

Seems like we have all been at it today,. Brian warned me about them allen bolts when we were out a few weeks ago, therefore expected the worse, so was surprised when they came out ok. Must have been my lucky day.

Simon, just wondering why you were taking the cover off. have you got trouble?

Mark

Padowan · Senior Member

It's on the missuses TTR, I need to get the starter to bits to see why it's not turning over.

Padowan · Senior Member

Got the bolts out this morning using a hammer and punch. Have already replaced then with some stainless ones (with a 5mm allen fitting) I had knocking around the garage.

TTRfan · Super Guru

Did you find the problem on the starter Simon and, if so, was it stuck brushes?

Brian

Padowan · Senior Member

Actually not yet. Having taken the gear cover off I was looking at how I'm going to get the starter out and I still need to take it out the "usual" way from the other side as I can't undo the terminal nut to remove the cable where it's currently situated as the post is spinning around (which might be an indicator of what's wrong of course). So after all that I'm now in the process of making space to pull the motor out properly. At least Ihave nice shiney bolts now!

TTRfan · Super Guru

I know what you mean. I ground a 10mm open end spanner down really thin so I can get it underneath the earth lead to hold it whilst undoing the top nut. Worth the sacrifice as its still usable.

I had to strip a TTR engine at the weekend and decided to see if it was possible to get the starter out from the RH side without disturbing the tensioner and, yes, it is!

It took a bit of force and wiggling but it does come out in a sort of near vertical position. If I tried it again, I would disconnect the clutch cable at the lever which is a really quick and easy job and then slip the outer cable out of its holder on the gearbox. Would make the job a lot easier!

Brian

Padowan · Senior Member

I found a nice thin 10mm spanner in my cycling toolbox.

Twas indeed a sticky brush. All fixed now and back together.

For info if you remove the carb (plus everything you need to take off to get that out), unbolt the oil pipe and disconnect the clutch cable, you can remove the starter without needing to take out the cam chain tensioner.