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Aut


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Hello from Maryland!
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Hello,

Picked up my 2002 ttr a few weeks ago and have been working to get her ready for riding the Colorado portion of the trans America trail in August.  So far things I've done: new chain and sprockets, stripped and replaced both oil plugs (drain and fill), and replaced oil and filter.  On the list to do: replace both wheel bearings, replace rear brake rotor and pads, install handlebar risers, install USB charging port, install heated hand grips, and finally figure someway to fabricate a luggage rack.  Besides the stripped bolts I replaced, there are two other things bothering me 1. Is my sprag clutch making noise? And 2, there is some oil leaking from the gasket where the jug connects to the crankcase - do I need to worry about this? Or just ride it as is?

Interestingly I was actually looking for a Suzuki dr350 and came across this bike in my search, without really knowing what a ttr was. They seem to be eerily similar!  Anyway I think it's the coolest bike.  I'm all about simplicity and reliability.

Aut

 

 



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Welcome to the forum, Aut.

Good luck with the bike come August so be sure to do the bearings , rotors and electricals well.

The sprag noise will be self aparent if on its way out - the leaking gasket depends on how much it leaks.

Mine wept for a few weeks than got stronger and messy before stripping down and doing. hmm

Martyn



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Budleigh Salterton. Devon

Aut


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Hi Martyn,

Thanks for the welcoming. When you did your gasket, did you end up changing any parts while you had it apart (like piston rings, etc)? Or did you just replace the gasket and that was it? How long did it take?

I appreciate the advice!


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To be honest, Aut, I did not do the necessary because I sub-let it out to my mechanic. biggrin

Brian, the site Guru, is a friend of mine, especially when he was a "friend in need".  wink

As I said, my base gasket had been getting steadily worse over about 3 months.

Whilst the head had to be removed it was checked over and de-coked. The opportunity was taken to fettle the bore and re-ring the piston.

                                                 

Combustion chamber.jpg

The leak                             

Cylinder base leak 5.jpg

The hardest part was the removal of the base gasket.

Cylinder base leak 4.jpg

The bore was OK after de-glazing   and the piston had a new set of rings placed.

Cylinder base leak 2.jpg

 

Brian also discovered why the bottom screw holding the oil filter cover on was not doing its job.  no

The screw itself had lost its thread rather than stripping the aluminium of  the crankcase. A replacement screw cured it.  aww

Martyn



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Budleigh Salterton. Devon



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Welcome to the forum Aut!
Congratulations on joining ttr world. Lighter and better suspension than a DR350, maybe not quite as powerful. (A 350 kit is being developed!) There is a DRZ250 which is the ttr's identical twin!
Some ideas for a rack here:
www.ttr250.activeboard.com/t60980288/load-carrying/

Leaky base gasket is no big deal if it is only seeping out. If it's running out and spraying on your boot whilst riding it's a bit more serious!

Starter sprag - the occasional clunk when you switch off is ok. Louder bangs need to be checked out (it's hard to describe what "louder bangs" is like over the internet, sorry) At least take off the starter gear cover and check that the gears in there are ok and not falling apart, then just ride the bike for a bit and get to know it.

Ride safe,

Simon.


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Welcome to all things TTR a great community of devoted fans to this fantastic bike. You will find all you need to know about them on this forumsmile

Like Simon advised if the leak is not to bad leave it until you do some other engine work, as for the sprag if it makes the clunk loud enough the you wince when turning it off, then it is time for a change, a small clunk sometimes is normal.

Steve



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Aut


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Martyn, Simon, Steve,

Thanks for the welcoming and useful information! Much appreciated


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YES I LOVE EVERYONE ON HERE SO FREINDLEY AND GREAT ADVICE YES AUT WHEN YOU GET THE FEEL OF THE BIKE IT IS WAY BETTER THAN ANY BIKE I COULD EVER ASK FOR IVE PUT OVER 23000 MILES ON MINE AND THATS REV REV REV WHEELIE RIGGOUROUS MOUNTAIN RIDING AND MANY WRECKS AND NEARLY TOATLED AND IT HAS HELD UP TO EVERYTHING GREATLY AND THE ONLY PROBLEM I HAVE IS THAT CRAPPY DECOMP. PLUG OVER THE HEADER LEAKIN OIL BUT JUST KEEP OIL IN IT AND IT WILL RUN TILL THE WORLD ENDS ITS MORE RELIABLE THAN A HONDA AND SOUNDS WAY BETTER TO AND MY BIKE IS THE SAME YEAR AS YOURS I LIVE IN THE US,TN ACTUALY MY BIKE CAN BE STREET LEGAL HERE I HAVE TO GET A LICENSE FIRST LOL BUT WITH STOCK GEARING AND UNCORKED IT IS BETTER THAN A YZ450F IN MY OPINION ITS FAST VERSITILE BUT I AM 6,3 SO THE ONLY THING I DONT LIKE IS THE WEIGHT AND THE STRESS IT PUTS ON THE SUSPENSION MAKE SHURE YOU LIFT IT IF YOUR GONNA DO CROSS COUNTRY OR HAIRSCRAMBLES BECAUSE ITSA LITTLE ROUGH PEOPLE LAUGH AT YOU AT TRACKS BUT NOT TILL YOU GET ON THE PODIUM WITH A STOCK TTR 250 LIKE DUDE GET OVER IT LOLL THIS IS THE BEST BIKE EVER AND THE REAL ART OF THIS BIKE IS TO KNOW HOW TO CLUTCH POP IT TO GET THAT EXTRA BOOST AND THE SWEET SPOT IN THE RPMS 3RD GEAR WITH STOCK SPROCKETS YOU SHOULD BE ABLE TO STAND IT UP EASY AND RIDE A 200 METER WHEELIE NO CLUTCH POP AT ALL FIRST 250 IVE EVER BEEN ABLE TO DO THAT WITH NOT EVEN A WR250 WILL STAND UP IN 3RD ON ITS OWN WITHOUT THE 310 KIT THE TTR IS ONE BADASS BIKE SORRY FOR CURSING BUT IT WOULD MAKE THE BEST END OF THE WORLD VEHICLE IN MY OPINION THATS HOW GOOD IT IS AND PRETTY FUEL EFFICENT ALSO LOLL BUT GREAT LUCK THOUGH THIS BIKE HAS ITS UPS AND DOWNS ITS NOT MADE FOR 50FT JUMPS BUT IT WILL DO THEM I TELL YOU THAT EASILY WELL I HAVE TO GO TO BED GREAT LUCK ON UR NEW BIKE

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