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Hi All

I have now actually started my first Totally TTRs rebuildblankstare

The bike is a blue 04, it has come to me in a bit of a statecry It will need everything done to it, including top end rebuild and rear shock overhaul, just to get me started.

I had 2 stubborn engine bolts that ended up taking nearly 2 hours to get outcry

A wise man said to me once, a bike in bits will take up more room than a bike that is nothmm and here is the proof

 ttr rebuild.jpg

Looking forward to getting it sortedsmile and as it is my first rebuild, I will make sure everything is done properly (start how you mean to go on!) even the carb is going to be rebuiltsmile

Steve



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Looking forward to seeing someone else do all the work for a change Steve wink

What colour are you going to do the frame?



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Good luck, Steve.

Does iot have a saddle?  confuse

Oh by the way - stardom congratulations to you and Lisa. Mrs Cubber and I saw you both on a house programme on TV the other night. No mention of TTRs though. no

Martyn



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Does iot have a saddle?  confuse

Eagle eyebiggrinbiggrinbiggrin

Someone else said we was on the goggly box last nightwink

 



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Frame now with ICS powder coaters in Cullompton, now I need to get on cleaning everything and doing a top end rebuildsmile



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Looks a good wee project!

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I had some much needed help today, the Guru came to visitsmile 

I had pre- ordered the steak pasties, just to keep his energy levels up!

So we set about the engine.....

IMAG1583.jpg

Always handy to have printed of the torque sequence!

We stripped all the parts off and found that the piston and barrel had been scoured

IMAG1591.jpg

Once they were removed we found that there was heat marks and scouring to the little end of the conrod

IMAG1590.jpg

Brian then tested the big end for play and we found that there was playcry meaning the crankshaft would have to be sent for repaircry This is a very unhappy enginehmm As luck would have it there was a whole crankshaft with conrod in excellent used condition in the stores and I decided to take it out of the shop and fit it to this bike, saving time for the crankshaft to be sent away for repair.

Next up we started to split the casing's to replace the crankshaft and found that the oil pump did not look so great, will be replacing this.

IMAG1600.jpg

 

Lot's of wear marks.

Now as for the clutch, think it has seen better day's

IMAG1595.jpg

IMAG1597.jpg

Now I knew that the engine needed a top end rebuild when I bought the bike, but did not realise I would be fishing around in the bottom end and in a funny way I am quite glad that I am having to do this, as I want to learn all from Brian that I can and we really are doing a full rebuild here.

Now when the casing's were split all the rest of the bearing's and gearing's have been fully checked and are fine (phew).

Kept the cam buckets and valves in a nice box, so would not lose there order in the cylinder head.

IMAG1592.jpg

Brian and I then got on with getting some parts back together, before we both run out of time, was 10am when we started and 6pm when we finished.

I will be putting all the parts of the engine back together over the next couple of day's, new barrel and piston will be fitted, really learning everything on this buildsmile as it is my first I will be doing everything thoroughly.

Thanks to Bri for all he's help todaysmilesmile

Steve



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Super Guru

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And a very nice steak pasty it was too Steve!

Regarding time, it's only fair to point out that we weren't working solidly on the engine for the whole 8 hours - lots of messing around with the computer, fetching supplies, and tea drinking as well biggrin

It would be really helpful Steve if, while it's still fresh in your mind, you could have a look at the guide here and let me know of any changes you think would help the first-time engine rebuilder please?

One of your next jobs is to clean up the valves coz they are massively coked up from the oil the engine was burning - a link is included in the cylinder head removal guide but it's here anyways.  

As it was your first rebuild, it was interesting to see what tools and consumables I use (and take for granted) that make life easier. Some are included here and here

Brian



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this is interesting....good luck!

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Will post up some more pictures soon, has been slow progress cry Kids they are time banditsbiggrinbiggrinbiggrin



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Indeed they are!! and wives!! lol

great thread looking forward to the updates

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ttr steve wrote:
A wise man said to me once, a bike in bits will take up more room than a bike that is nothmm and here is the proof
Steve

 Kind of true But I have nearly my whole DRZ400 stored in a 4 draw filing cabinet and ontop of it biggrin



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BM Steve wrote:
ttr steve wrote:
A wise man said to me once, a bike in bits will take up more room than a bike that is nothmm and here is the proof
Steve

 Kind of true But I have nearly my whole DRZ400 stored in a 4 draw filing cabinet and ontop of it biggrin


 I hope its stored in files in alphabetical order. 



-- Edited by leigh on Friday 11th of November 2016 12:09:13 AM

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leigh wrote:

 I hope its stored in files in alphabetical order. 




 Of course, that goes without saying biggrin



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Got the engine all back together now, after a serious amount of work!

Parts replaced inside the engine

Clutch plates

Pressure plate

Oil Pump

Crankshaft

Piston and barrel

Valves lapped

Sprag and Idler gear checked, Have I missed anything? Oh yeah cam chainsmile

Putting the valve collets in was so easy with my new tool

small valve tool2.jpg

Just put everything in and push down!

Small valve tool.jpg

After all that work, a nice spray job for a like new enginesmilesmile

engine.jpg

Note the top of oil cap, to protect where the starter should bewink

 



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Nice job of the engine Steve!

The collet tool is a God send - I have used mine a few times now and it makes a fiddly job soooo easy biggrin

Not a quick job a full restoration eh?

Brian

PS Having spent a day on a TTR today, I am having a "play day" on my A10 tomorrow wink



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Oh and I checked clearances and re shimmed as necessary.

Liked the tool so much I am now stocking themsmile

 http://totallyttrs.com/epages/699105d9-e4cc-4b32-b236-84e72cd67f84.sf/en_GB/?ObjectPath=/Shops/699105d9-e4cc-4b32-b236-84e72cd67f84/Products/TTR-0672



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Just found this picture of me lapping the valves in, this tool makes it so much quickersmile

lapping in.jpg



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Brilliant bit of work, Steve.

You and Brian make it all look so easy and straightforward, thanks for all the pictures and information.

Martyn



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I have been busy cleaning parts and getting ready to put the bike all back together.

Amazing at how many thing's I have had to put right, good learning experience for mewinkwink

Will post up some more details and photos soonsmile

Looking forward to running the bike in, as a lot of work has gone into the engine re-build.



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Great interesting thread. The rebuild threads have always been my favourite. What colour is the frame going to be ?

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Hi Andy metallic blue, just like the originalsmile



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Finally got to start putting the bike back together this morning!

Started of like this at 8am

rebuild 2.jpg

Moved onto this

rebuild 3.jpg

After I had replaced all the

Swing arm bearings

Linkage bearing's

 Top shock bearing with the one of the kits that I sell https://totallyttrs.com/epages/699105d9-e4cc-4b32-b236-84e72cd67f84.sf/en_GB/?ObjectID=1718485

Then Brian turned up to land a hand and give me some moral supportsmilesmile and drink tea! No pasties as we are both on a new year / new health kicknono

rebuild.jpg

I have replaced all the wheel bearings

Checked and re- greased the steering bearings

Fitted new brake pads front and back

Fitted new grips and Handguards

Finished work at 10pm and now looks like this! Yes I know my tools are messy, will tidy up first thing in the morningwinkwink

 IMAG1844.jpg

IMAG1846.jpg

 



-- Edited by ttr steve on Monday 9th of January 2017 11:18:55 PM

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Well done for carrying on with the build Steve - excellent progress. Should be running by tomorrow lunchtime wink

Presumably you will be putting it up for sale when finished and run in? I can imagine that there might be a few members interested in buying a frame up rebuild like yours.

Brian

PS Missing the pasties cry



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Yes this bike will be for sale, when finished and I am off to do some more now.  Fitting all new plastics Kitsmile 

Will be like a brand new bike, but better, as it will have a motad fitted with the shorter header pipe and the lovely wide stainless steel foot pegs that we do https://totallyttrs.com/epages/699105d9-e4cc-4b32-b236-84e72cd67f84.sf/en_GB/?ObjectID=1718295

 

Steve



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More progress todaysmile

Fitted New headlight

 New Front mudguard

New Rear mudguard

Finished back of bike wiring

Fitted cleaned up carb

New air filter and plug

New case saver

New side cover, starting to really enjoy this bit as the bike looks like newsmile

 

IMAG1873.jpg

 

Steves TTR.jpg

 

iIMAG1868.jpg

 Sorry the picture of the case saver is rubbish, I really need to upgrade my phone!

Better picture of the Case savers available here https://totallyttrs.com/epages/699105d9-e4cc-4b32-b236-84e72cd67f84.sf/en_GB/?ObjectID=1718310

I am going for a blue black colour theme and will leave the plastics sticker free! as they look so nice brand newsmilesmile

I have fitted the original indicators, but I could change them for smaller ones, if the buyer prefers, I would do this free of chargewink

Steve 



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Not done to much todaycry

Got the electrics all working, to find out the  aftermarket headlight I thought I would try, turns out to be rubbish.

Back to polisport me thinks!

All the rest is working perfectlysmile



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That looks pretty nice, they look great with nice new shiny plastics don't they

what tyres are you running there ?

woudn't mind giving a trials pattern a go

 

..



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Hi Steve

Mt43 front and back.

Would think the new owner will want to add their own rubber, so just put on what I had.

Though most people around here run mt43 on the back and mich comp 4 front.



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Just seen this in the flesh and decided I couldn't live with something so new and shiny with lots of lovely well thought about extras.
This is the epitome of a nut and bolt rebuild and compared to other bikes in the same condition (New WR?) Will be a right result for the new lucky bastard.....

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Cheers Rich

Nice to see you todaysmile

Got the new headlight today and number plate. Of out on MY bike tomorrow, so wont be doing any more until Sunday.

Motad and Shorty header pipe to fit next, just to give that bit of extra punchsmilesmilesmile This bike is having all the bells and whistles fitted eyepopping.gifeyepopping.gifeyepopping.gif

Some lucky person will be getting one of the/ THE best TTR's out therewink

Looking forward to running the bike in, even though I will have to go around the lanes and not ride themnono No way I am going to scratch it!



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Looking good now Steve. Nearly there! The 2 tone headlight looks better than all 1 colour I think.
Will you find it difficult to part with it?
I'm still waiting for my tank/plastics to be painted black. Don't mind waiting for a favour job, but it's getting silly now. 'Course, I won't be selling mine, just permanent loan to my bro in the garage next door

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IMAG1882.jpg

Fitted the decent Polisport headlight tonight, much bettersmilesmile

Next up the motad and Shorty header pipe, just to give this little bike a bit more punch

 

 

 

IMAG1884.jpg

IMAG1886.jpg

Then another new plastic fitted.

And I have finished for tonight.

IMAG1887.jpg



-- Edited by ttr steve on Monday 16th of January 2017 11:55:14 PM

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Booked in for a MOT tomorrowsmile



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Will you be crossing Mr Treens palm with silver for that ticket If so when you are in there ask Clive about his TTr Raid he is about to put it up for sale an it's a runner well maintained just a bit cosmetically challenged don't offer him more than £800 for it as I could have had it off him for that.

Martyn

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Ye Treens is the place

His bike sounds like me - good runner but cosmetically challengedbiggrinbiggrinbiggrin

I need to sell a couple of bikes before I even think about buying anothernonono



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IMAG1891.jpg

Frame guards fitted, tail tidy fitted back end is looking very nicesmile

IMAG0002.jpg

At last, she has made it out of the garage!

Took her to treens for an MOT  http://www.treenmotors.co.uk/

 A proper bike shop run by people with engine oil in their veinsbiggrinbiggrin

One advisory Brake pedal pivot bolt worn, will replace!

The bike ran so so sweet, no rattles bangs crunches or mishaps. Nice and smooth up and down the gearssmile Really looking forward to running this bike in, is a real treat.

This will be the ultimate TTR for some lucky person, not only have I fully rebuilt the engine ( with new piston and rings) and powder coated the frame, it has had all new plastics and all the extras someone could want.

Bashplate

wide footpegs

motad

shorty header

tail tidy

case saver

frame guards

gripper seat cover

complete bearing replacement (apart from steering ones, they were checked and re-greased)

If anyone is interested on this forum please let me know, otherwise it will be advertised on the Devon TRF forum, the National TRF forum and the dreaded flea bay! Very soon.

Steve



-- Edited by ttr steve on Friday 20th of January 2017 06:01:04 PM

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Did the bike pass?

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Hi Dan

Was writing the report while you posted!

Forgot to say, new tank graphics will be addedsmile



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Great news, looks great!

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pug wrote:

Will you be crossing Mr Treens palm with silver for that ticket If so when you are in there ask Clive about his TTr Raid he is about to put it up for sale an it's a runner well maintained just a bit cosmetically challenged don't offer him more than £800 for it as I could have had it off him for that.

Martyn


He has an OE and seems interested keeping it, now I told him about the 350 kitwinkwink 



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Good job matey

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Yes looks great, you've done a good job . Well done.

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Yep you are right Steve I saw him Friday tea time said he had asked you about the clock pickup He wanted to flog it to me last weekend now looking like he wants to keep it what can you say. he has a WR 250 / KDX 200 / KTM 250 for the lanes an still likes to ride the TTr something needs to go to fund his XL 500 rebuild Life is full of hard choices .....................................

Martyn

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pug wrote:

Life is full of hard choices .....................................

Martyn


I totally agree with you on your ultimate statement, Martyn. wink

My choice this cold, chilly morning was "Should I get out of my nice, warm bed?" confuse

 

Brilliant report on the rebuild, Steve, complete with coloured pictures.

A labour of love and looks better than a new one., but don't get it mucky on a trial run. disbelief

Martyn

 



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seems like a great tool for lapping the valves. How this tool is called? I want it.

 

 



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honda15i wrote:

seems like a great tool for lapping the valves. How this tool is called? I want it.

 

 Oscillating valve lapper  can be found on eBay 


 



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thanks. I found it.

 

do not buy this

http://m.ebay.co.uk/itm/Performance-Tool-W80571-Valve-Lapper-1-1-8-1-3-8-/141043500503?hash=item20d6d905d7%3Ag%3AEaAAAOxyaoFSFih8&_trkparms=pageci%253A2046085f-fb73-11e6-b5c0-74dbd180f675%257Cparentrq%253A75fdde5f15a0a7873950b58afff95084%257Ciid%253A29

 

this one is a crap.

 

 

 

 

 

 



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That's a traditional method and tool a freind of mine will not use anything but. He builds race and competition subaru engines and only ever does valves by hand this way 😂

 



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