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Here's my first ttr "ground-up" (last resto was a ccm 644 - lovely bike but riding it just didn't inspire me like the ttr doesno)

As bought:

012.JPG013.JPG

 

As you can see, she's been leaning against a wall for a whiledisbelief Time for the hot air gun and the massaging hands!

Powder coater's tomorrow...



-- Edited by mossproof on Wednesday 3rd of May 2017 08:24:32 PM

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What colour you doing the frame Simon?

Interesting to see how good the anodising on the barrel is. It was certainly better quality on the older TTRs!

Brian



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Black. Colour scheme was either going to be black/white/red (love the old tt/xt look) or black/gold JPS stylee. My brother has expressed an interest, particularly if it becomes a 325, and his preference is the black scheme, so there we go...
Wish I could find a durable cheap way to turn the rims gold. Reanodizing is the way, but respoking/rebuilding is the cost... (I don't feel up to it myself)
You're my inspiration Brian, it's all your fault!-)


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Looking forward to seeing the OE resurrected.

Good luck Simon.

Looks like there's a few of us doing restoring at the mowink



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mossproof wrote:

Wish I could find a durable cheap way to turn the rims gold. Reanodizing is the way, but respoking/rebuilding is the cost... (I don't feel up to it myself)
You're my inspiration Brian, it's all your fault!-)


Just sold a pair of gold rims cheap!!!

Ask your powder coater - my powder coated silver rims are working out well.

I'm not apologising for inspiring you Simon - it's great to see another TTR being kept on the road rather than being broken for spares biggrinbiggrin

Brian



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Do you find the coating robust enough to withstand tyre irons Brian?

Yes, hate to break a bike if it's got potential. I paid basically the price of an engine for it, so the rest is a bonus, and as it was unregistered it was tempting to sell the bits to be left with a free engine, but I felt the urge for a new project, and my bro is beginning to feel the weight of his lightly modified xt660z tenere on our longer 'laning trips (we're none of us getting any younger!) and enjoyed his time on my 325 on the A2E, sooo...

Thanks Steve! I'll be alone in my shed while you're waxing on, waxing off with the ttr dojo's head sensei, and borrowing his tools!-) (I was going to use a star wars analogy, but we've already got a padowan on this forum!)

Simon.



-- Edited by mossproof on Sunday 6th of March 2016 08:24:10 PM



-- Edited by mossproof on Sunday 6th of March 2016 08:24:49 PM

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mossproof wrote:

Do you find the coating robust enough to withstand tyre irons Brian?


 I am using the rims on my shopping TTR. 

If you were going to do it, take the rim off and just get that powder coated, I did the hub, spokes and rim at the same time and it wasn't the best plan in retrospect.

The downside was that, although the spokes were tight when I passed the wheels over, the shot blasting must have loosened them. This was hidden by the powder coating for a while but eventually the spokes worked loose so I stripped the wheel down and fitted a new spoke set. no

See http://ttr250.activeboard.com/t43731716/modernising-a-1993-yamaha-ttr250-open-enduro/?page=3#lastPostAnchor 

So the tyres have been changed a couple of times with no damage to the powder coating. 

Brian



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Looking forward to seeing how you get on with yours, mine has taking a while lol

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O.. it's a motor bike...
by the heading I thought you got marryed or had a kid...

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LOL!

Which is worse?

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I know which ones cost more!

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THE WIFE!!!!!!!



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A bit of progresssmile

Frame black powder coated - happy Martyn?biggrin Rear shock regassed and resealed, with new bumpstop fitted and spring recoated. (Revs Racing in Halesowen highly recommended) Front forks resealed and fresh oil. Rear swingarm all new bushes/bearings and repainted. Mitas 644 Army Special front and Mitas e08 rear tyre (an experiment - not sure about the rear yet...) New headstock bearings. Renthal hi-bars. New rear wheel bearings and seals. My Indian special headlight conversion.

I chickened out of spraying the forks and swingarm gold but I think the rims will turn gold one way or another in the end. The engine's still in my other ttr being tested. Cleaning/painting that and refitting is next.

Further plans are Koso digital speedo; (I have a Trail Tech Endurance on the 325 so this is purely for scientific reasons - I'll post comparative results when I have them!)Aftermarket L/hand switchgear which incorporates h/light off switch. Standard exhaust will be going on because I've got one. Would love a quiet, light, free flowing aftermarket pipe - dream oncry Anyone tried one of those Polish Dominator exhausts on ebay?

ttr 003.JPG

Ride safe,

Simon.

 



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mossproof wrote:

Frame black powder coated - happy Martyn?biggrin

Simon.

 


 Definitely, Simon.

That looks, to me at any rate, much better and more distinctive than TTR blue.

What colours are you contemplating for the saddle and tank?  confuse

Martyn



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In the short term, I'll fit my white OE tank and blue seat to get things rolling, but I have a tank to refurb which will be black, hopefully with gold graphics and I have yet to source a seat and side panels, all of which will be black.
S.

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Looking good there mucker, looks good in stealth mode

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Oh you went with black fork gaiters, pity, I really like the white ones, If I do a rebuild on mine I'll go white I think

 



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I love black and gold - JPS stylee biggrin

You have put me to shame Simon. I have hardly touched my rebuild. Too too many distractions!!!!

Brian



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Anyone ever done a rebuild with black swingarm and linkages ?

Can't say I ever saw one confuse

 

..



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The factory black TTR still had silver swingarm. I haven't seen anyone with one - think it might be overkill a bit, unless they were going for the matt black radar proof military look!
RE white fork gaiters, they might look odd on my bike as nothing else will be white in the end.
S.

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That is really looking nice Simon.

Where did you get the black plastics ???



-- Edited by ttr steve on Saturday 7th of May 2016 09:04:14 PM

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Thanks Steve. Front mudguard is Polisport from ebay. I had to heat it and do a bit of modifying to get clearance for the cable run under the headstock as I couldn't find anything aftermarket with the same depth groove as the TTR. All the other plastics are/will have to be originals painted up - large amounts of keying with wetordry, plastic primer and top coat. Don't know how it will cope long term. Keeping it nice might be a bit high maintenance but there's no option. I've even tried to look on Japanese websites for the black model - "hahahahaha" is the response to that!

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mossproof wrote:

RE white fork gaiters, they might look odd on my bike as nothing else will be white in the end.
S.


Yep I agree, black is the go there

So a powder coated frame, what about the wheels, the front is still purple in the picture I think, bit hard to tell about the back wheel

You could try black vinyl on the plastics if the paint proves to be a problem, stretch it till it fits with a hair drier

Nice job so far

 



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Thanks. Have thought about wrapping the plastics. If the paint all comes off on the first pressure wash, that's the next plan, although I don't know if the wrap would come off with the hot wash?
Wheels are still purple so far. The pic Brian has of the factory black model (was it a '97?) has purple rims anyway, but I'd much prefer gold. I have a gold DiD 21" rim from an XL600 that I am going to try and lace up to a TTR hub, but haven't yet located an 18" rear (XL600 was a 17" I think, but I haven't got one anyway!) I will get it road registered before I go too far in that direction.
Next job is getting the engine painted and back in, then I will feel I've made some proper progress - today's just been a day of painting clutch and brake perches and pondering wiring modifications.

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Wrapped panels 001.jpg

I have only ever seen panels wrapped once as shown in the above photo. My recollection is that the wrap looked and felt like it would take a lorra stick...

Not expensive - see http://www.ebay.co.uk/itm/BLACK-GLOSS-FINISH-CAR-VINYL-WRAP-VARIOUS-SIZES-AIR-BUBBLE-FREE-/331294350143?_trksid=p2141725.m3641.l6368 



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Taking a break from the concentration required for wiring in a new L/H switchgear with incorporated lights-off switch, and puzzling the necessary feeds for the Koso speedo, plus fitting mini relays for the 55/60W H4 headlight bulb. It's not pretty, but there're no smoke leaks yet!

wiring 002.JPG

Note new horn position, out of flying mud's way.

Ride safe,

Simon.

 

 



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Black and white's growing on me! Anyone able to photoshop the tank and seat black and the rims gold to see how it might look?

001.JPG

 



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Not my best job but it may give an idea

001.jpg

Martyn






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Looking good Simon (and Martyn!) biggrinbiggrinbiggrin

Engine looking particularly good against the black frame.

Couldn't help noticing you are still using a 6-plate clutch cover whereas a later clutch cover would give to over 100cc of extra oil in the sump - good for a 325 engine wink

Brian



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Getting there, do like the all black looksmile

Did you spray the foot pegs?



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Thanks all, good work Martyn!
Brian, I'm trying not to spend on nonessentials 'till it's registered (hence no handguards yet) but it's in the plan. Would a later clutch fit as well for the extra torque?
Sprayed the footpegs gold. Should have done the brake and gear levers too I suppose
The Koso speedo sender is the current head scratcher. The Trailtech Endurance 2 uses a 2 wire ("non active") sender reading a magnetic brake disc bolt. The larger Koso units do too and the sender is easy to position out of the way. The smallest Koso uses a 3 wire active sender like an abs sensor and is proving hard to locate in a non vulnerable place. I'll take pics sometime. Apart from that, bleeding the brakes and fitting the chain and header pipe, she's ready to MOT, as long as the jetting is ok (carb came with 48/142 jets).
Cheers all,
Simon.

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mossproof wrote:

Brian, I'm trying not to spend on non-essentials 'till it's registered (hence no handguards yet) but it's in the plan. Would a later clutch fit as well for the extra torque?


Yes - you can upgrade the 6-plate TTRs with a complete basket and the later deeper clutch cover wink

Good luck with the MOT!

Brian



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Got her registered finally! Age related plate, L registration. Only problem is they've put TDR250 on the document under "model". All the paperwork now has to go back to prove they can't read, rather than it being my fault.

Got a lovely tank in good condition about to go to the paint shop. I tried wrapping the side panels - looked good for a few days then the wrap started delaminating where it was stretched a bit, and shrinking away from the concave corners. Not happy with that so my paint guy is going to do them and assures me his plastic primer is good. We'll see...

Anyway, currently this is the look. I do like the black and white LAPD look, but all black is going to be the final scheme.new ttr 002.JPG



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Hi Simon - she is looking good!

Presumably now registered you can ride it and check out the motor?

If you are going all black then you definitely need gold wheel rims wink

Brian

PS I had some wrapped panels back along and they seemed to have held up OK despite some obvious damage under the wrap - maybe your wrapper was on an apprenticeship?  biggrinbiggrinbiggrin

 Wrapped panels 001.jpg



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Ran this engine for a while in my 325 to test it and it's a good 'un, unlike one I bought recently from a forum member which has no compression whatsoever and is awaiting a stripdown when I get some more round tooits. (They're on back order!)
Wrapper was definitely an apprentice - me! But I see on your pic it hasn't stuck along the seat line, or in the concave above the vent hole - exactly where mine's coming away, only mine's worse and shows up more in black. Paint for me...
Got a gold front rim that needs lacing. (If anyone has some new old stock round tooits I'll take 'em off your hands!) Rear I'm still looking for...
Ride safe,
Simon.

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Yay! DVLA have supplied an accurate V5 registration doc. I'm now a 2 TTR250 man. Shame it's insured as a TT250R but you can't have it all! Waiting for tank to come back from my paint man. Should have been yesterday but he is a perfectionist so I'm happy if it takes longer. The I just need to get custom tank graphics - I want to copy the one's on that Chileno ttr but using gold/silver instead of the purply red, then relace my gold front rim, source a rear gold rim, put in a 325, or 350, and let my brother loose on it! Pics to follow when the tank's here...
Ride safe,
Simon.

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Finally got the side panels and tank back from the paint shop. Self made graphics on, next is clear wrap in the vulnerable areas. Gold wheels continue to evade me...

black 002.JPG

black 001.JPG



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That is looking so niiiiiiiiiiicesmilesmilesmile

Agree with the Gold Rims.



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Wow - gonna look amazings Simon biggrinbiggrinbiggrin



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Looking really good Simon, black rims would look good too IMO.

I always thought the white Open Enduros look better than the blue ones.  

 I reckon one could look good with the white plastics, and fuel tank painted silver with retro Yamaha graphics like an old XT or similar.   So all black white and silver.



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Thanks guys.smile
Advantage of the OE, and Raid, is an easily paintable tank! (To side track onto another fetish, the OE tank with paint, stickers and wrap but no tap or cap, is 2kg on the bathroom scalesbiggrin)

Nice looking xt, is it yours? I quite fancy one as a project while I'm waiting for the 350 project to move on, but even basket cases have gone stupid money here. And I take it from the for sale section that you're happy with the usd forks?

Ride safe,

Simon.

 



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Well here she is in all her glory:

bandg 001.JPGbandg 002.JPG

Rear tyre is now Maxxis IT M7305. It's a 120/100x18. Only just fits - should have gone for the 110/100 which would have been plenty big enough. The E08 just wasn't cutting it in the slippy stuff and I don't like the rear Army Special on my bike - just can't get it to stop vibrating over 45mph. Front tyre still Army Special.

The gold rims are the original purples reanodized and rebuilt by David Alexander - I will post separately with his details in the modifications section...

Now down to my brother to keep it rubber side downsmile My work here is done, for nowbiggrin

 



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Very, Very nicesmile

Is it Giles bike then?

Hope he appreciates all the work you have donewink

Did you make up the frame guards?

I would be interested in stocking themsmile they look really nice!

Avery nice job and a real credit to your workmanship.



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Well worth the effort Simon - excellent job!



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Thanks guys. I'm very pleased with the result.
Steve, Chris is my bro, Giles is the other ttr rider in our gang. Chris says it's like being a works rider - he comes out of the house with his roll bag of gear and the engine's running, oil checked and tank full! (It's actually the only way to leave home on time!)
The frame guards are 1mm ally cut to shape from a cardboard pattern and bonded onto the frame with pu sealer (automotive body seam sealer) taking care to eliminate gaps where water could get between frame and guard. They're a bit of a labour of love really.
One day this bike will inherit my 325 engine when the 350's running. If Chris wants it 350 he can splash some cash!
Got to go, running on battery as we've got a power cut to repair Storm Doris' damage. Ride safe,
Simon.

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Chris is a lucky fella to have a brother like yousmile

Don't think I would do the same for mine!

Think I will just nick your frame guard idea then, If you don't mindwink

I will compensate with beer tokensbiggrinbiggrinbiggrin



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That looks fantastic, well done.

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yes that pretty dam fine... got a chunky look about it...




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It certainly has the classic JPS look wink

John Player Special Lotus.jpg



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