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Hi all. I wil be posting my progress on my bike in this thread. Feel free to comment and guide me during this process. I'm not promising daily updates, I wil try though. To see were it all started, check out link below. 

http://ttr250.activeboard.com/t63655977/newbie-from-south-africa/

 

Update number 1:

I've paid a visit to our local yamaha dealer, gave him some cash in exhange for some parts. ZAR2583 for the following parts. 

Oil filter
Outlet valves.
Valve stem seals
Top end gasket set. (O-ring etc...)
Timing chain
Spark plug

In the meantime while I wait for the parts to arrive, I've started cleaning muck and dirt from the engine. 

 

I also found that the magnet in pick up was slightly broken. Didn't order that part disbelief

20170617_184111.jpg20170617_180902.jpg20170617_185550.jpg

 



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Sorry for landscape fotos, posting from my clever phone. Just to let you all know, I bought the bike as fixer upper, already spend almost more on the bike than what I paid for it. Have a lekka fathers day you all!

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Update 2

Stil waiting on the parts. Nice guy at yamaha said I should have it by Wednesday.

Starting to prep for the cam chain replacemen, opened up the side cover only to reveal a nasty surprise. Can anyone tel me what the below muck is? It feels like stone chips, how could that have gotten into the motor? And the black pieces are bits of plastic? Everything stil looks fine inside the motor including the cam guides.

20170619_191414.jpg20170619_191427.jpg



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20170619_192447.jpgDoes this look normal???? Please tel me it wil all be ok?cry 



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looks like cam chain slippers to me

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by the way order your parts from totally ttr s never mind a yamaha dealer when you want advise they cant be bothered but steve or brian will be helpfull just my thoughts anyway john

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If the black strips are hard rubber then Johnny could be right - the side guides off a slipper. Have you had them both out to check? Perhaps post some photos of them so that we can compare with good examples?

The wear marks on the crankcase seem to show that some sideways movement on the cam chain has allowed it to rub against it.

Are the metal bits aluminium or steel (magnetic)?

I think it may become clearer when you get further into the strip down.

Brian

PS It will all be OK wink



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JOHNYBOY wrote:

by the way order your parts from totally ttr s never mind a yamaha dealer when you want advise they cant be bothered but steve or brian will be helpfull just my thoughts anyway john


 I wish I could, but shipping and customs clearance to South Africa is a nightmare. Might end up paying double the part`s price. 

 



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On closer inspection, i found that it was indeed the chain slipper`s side guides that came off.

Wil now replace that as well.
Im just worried, why did all this stuff happen? Dont want to replce all the parts, but i dont have the root cause of failure?? And I spoke to the previous owner of the bike this morning, and he told me he had the Camchain and valves replaced about 6months ago. Told him that he was taken for a ride,and i showed him that all the parts in this engine is old. It was a buddy of a buddy that helped him out. Ya sure..... I smell B.S.


20170620_065832.jpg20170620_065848.jpg



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TTRfan wrote:

If the black strips are hard rubber then Johnny could be right - the side guides off a slipper. Have you had them both out to check? Perhaps post some photos of them so that we can compare with good examples?

The wear marks on the crankcase seem to show that some sideways movement on the cam chain has allowed it to rub against it.

Are the metal bits aluminium or steel (magnetic)?

I think it may become clearer when you get further into the strip down.

Brian

PS It will all be OK wink


 

I found this pic on one of your olders posts, 

Looking where the red arrow is pointing, is that a Lip or a edge that the Chain Slipper should push against? Cant really see, and my casing is worn, so im not sure if i should have it or not? 

 

 

Timing_chain_fitting9.jpg



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Not sure what the earlier photo showed but there isn't any sort of raised lip on the casting I just looked at. See photo below.

I can't think why the slippers should have been damaged in that way unless there was more end float on the camshafts than there should be.

Did the cams and cam caps look OK - does it look as if either or both of the camshaft sprockets might have worked loose at some stage?

Brian

PS Was the metal swarf magnetic?

BrianTiming chain crankcase.jpg

 



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Just got some bad news from the dealer. Lead time for a new slider is 6 weeks.

How soon can total ttr supply one to south Africa? And price? Should I order via their website?



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Totally TTRs can also supply good used parts.

Front slider here:  https://totallyttrs.com/epages/699105d9-e4cc-4b32-b236-84e72cd67f84.sf/en_GB/?ObjectPath=/Shops/699105d9-e4cc-4b32-b236-84e72cd67f84/Products/TTR-0525

Rear slider here:  https://totallyttrs.com/epages/699105d9-e4cc-4b32-b236-84e72cd67f84.sf/en_GB/?ObjectPath=/Shops/699105d9-e4cc-4b32-b236-84e72cd67f84/Products/TTR-0524

Steve can normally get genuine Yamaha parts in very quickly but only if the Yam dealer has them in stock.

Regarding shipping time, the UK Royal Mail service will usually get Airmail parcels on outgoing flights within a day or so.

I found in the past that the slowest part of the delivery is in the receiving country.

It depends on good is the SA PO at getting stuff to you normally as that would probably determine the total shipping time.

Brian



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TTRfan wrote:

Not sure what the earlier photo showed but there isn't any sort of raised lip on the casting I just looked at. See photo below.

I can't think why the slippers should have been damaged in that way unless there was more end float on the camshafts than there should be.

Did the cams and cam caps look OK - does it look as if either or both of the camshaft sprockets might have worked loose at some stage?

Brian

PS Was the metal swarf magnetic?

Brian

 


 It just looked on the first picture that there is a lip, Might just be the angle or oil on my glasses.  Im just relieved that there shouldnt be a lip.  Cam caps, NO, the exhaust side is NOT OK, wil post a picture later today, dont have one with me now. Looks like it was mutilated and patches up with with some resin kind of goo. 

Cam gears 100%

Regarding the swarf, no, it wasnt magnetic. so i can rule out worn crank or bearing right? 

The oil filter collected most of the swarf. 

20170615_192151.jpg



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Swarf must be ally then, from the damage to the crank case, which was caused by the sliders having no edge. I would imagine this has been caused by a very worn cam chain and maybe the cam chain tensioner not working properly, thus letting the cam chain flap about.

I have been warned not to post anything to South Africa, that does not go by UPS and such like. As the post system out there is a bit chaotic. I do post to customers out there, using the courier and they have always arrivedsmile

Steve



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20170620_181945.jpg

 

You are right Steve, the SA post office is a no go. I've placed the slider in my basket on the website, will place the order in the next day or day two, just checking if I might need some more parts.

We can start of with the exhaust cam cap as well. Do you perhaps have a spare one?

Don't know what these okes thought



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Cam caps are not available to buy new and rare as hens teeth second hand.

I do not have anycry

Best post up on the wanted part of this forum



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Guess one one is the new chain? I'll give you a hint.  It's not the left one. 

20170620_202207.jpg



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pull the right one check the length also side movement

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ooooooooo noooooooo what happend my bike did that but i got the drain fixed and always use the stock filter fidget with the oil galleys a bit

dude you always gotta run clean oil in these bikes i change mine every 300 miles or 600 if shes gettin good in

10w40 luchas pro motocross oil and im thinkin about gettin a oil cooler idk if they even work tho i am going to exaust wrap the header

i run 103 octane in mine and never has any engine problems and that timing chain has to be tightbleh and the cam caps torqe them to 7.5 ft lbs 

lash should run .35 at .000 mine starts first tap of the starter and idles perfect needs a new throttle cable its done wore out and i will have recent great ideas for this bike soon

i have a great look for this bike and a motocross setup where the seat is up to my abs and it has weight reduction need to get rid of that pipe lolevileye have ideas of putting a shorty baffle on it

i have straight piped my bike and im building a custom muffler for it

i will have updates within 5 days it looks sick ive found a great lowered hard tail desighn for this bike

i painted the frame flat black it has the shocks flouresent yellow im going to paint the hubs and rims flat black and spokes that yellow it looks sick

still blue plastics and the lowered shock and hardtail looks insane still utilizing all mounts and quick easy ilistration  were talking lower than a harley

and its great for the street side and the extreme dropped shock will be great for raid and street low tuck low profile street moster and ready to dive off the road now i have it lifted so much 

the sag i set at  '1  ''  1/2 its as high as a 450

and the suspension is highly tuned all  stock too this is the best stock suspension ever hydraulic sucks id way rather have airbiggrinbiggrinbiggrinbiggrin



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Please never stop posting.... I so look foward to reading your posts....

 

 

 

 

..



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O yer and a Quad...



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20170620_170142.jpgHey Guys

Its the weekend, Got most of my parts and im ready to rock.

Still haven't ordered the Cam Chain Slider, as I Might be getting one from a buddy of a buddies nephew, wil be going there to check out the condition!

Plans for the weekend is.

NEw valve stem seals
Lap valves (2 new outlet valves)
FitBarrel, head and new cam Chain.
Fit motor back into frame,
Clean the hell out the bike, Concentrate on Front END, Shocks etc... )

If i cannot find a Cam Chain by the weekend, i will still carry on with the above, but will keep the covers open until such time i can fit one.

New parts..



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So the weekend is coming to an end, Sunday evening blues kicking in. 

I didn't get done what I set out to do. It crossed my mind that I cannot reassemble the engine without the cam slider, and the one I went to look at was also a dud. So I have placed the order with our local Yamaha team, and they promised 2-3 weeks. 

 

What I have done is the following.  I went to town on the front end with my 10mm socket. 

 

Triple clamp: need to replace bearings,had to order them because they not standard according to our bearing supplier. That sucks

Cleaned all the parts in my wife's parts cleaner in the kitchen. Pretty good piece of machinery that is. And then I sprayed what I could with a nice silver hardworking automotive spray. 

I hate the fact that I need to sit around and wait for parts to arrive, feels like my life had got no meaning.    no

 

Clamps Before

20170623_210307.jpg

AFTER 

20170625_114731.jpg

20170623_210249.jpg

20170624_165845.jpg

 



-- Edited by Vormoto on Monday 26th of June 2017 08:02:12 AM

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20170624_165841.jpg

20170624_165856.jpg20170625_114716.jpg

 



-- Edited by Vormoto on Monday 26th of June 2017 08:03:41 AM

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I love these project threads. Keep it coming!

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'94 Yamaha TTR 250 Raid (with Open Enduro headlight, grrr...)

'54 plate Suzuki GSF 650S (Bandit)

Previously Yamaha YBR125, Yamaha TY125, Yamaha TY250



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pedrosan wrote:

I love these project threads. Keep it coming!


  I wont stop posting, but is is ridiculous how I need to wait for simple stuff. Only Received Steering Bearings today, So i can start fitting the tripple clamps back on. 

Wont be able to fit the shocks back on yet, as i need to WAIT for Shock Protector Boots, MIGHT get that later this afternoon.cry

This is simple stuff that is supposed to be off the shelf at any respectable bike shop.  but its not! Everything i have needed for my bike thus far needs to be ordered, Its like the Bike shops are relying on customers to carry thier business, and they dont want to carry stock. Stock is money laying around.... 

But nevertheless, I`m still in high spirit!  Bike will be Completedbiggrin

 

 



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Update: 

Fitted new Fork Boots, Sanded and sprayed plastics.  I really like using this Rustoleum Product, its quite flexible and durable.  Cleaned up my Headlight lens, look sliek a brand new headlight. 

Found a Yamaha TTR RAID  for sale on gumtree. Advertised as Excellent running condition. Will be checking it out tonight, and if all goes welll, I migth have a second TTR. Seller is asking R19,000 (1,200 in Funny money, Im hoping to offer 900) 

 

20170630_184522.jpg20170630_184446.jpg20170702_192229.jpg



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looks spectacular man i think these bikes are the best they look good nomatter
what you do to them does that wite look good and im thinkin about painting my
plastics orange blue and yellow or all black and blue with dabs of that flourecent
yellow on the front forks look good asfffff paint the rims and frame u will be in love
with the way she looks the flourecent is something to look at and a sparkly base coat
with tons of layers of clear mannnnnn wow i love the ttr

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to get that stripped drain plug out drive a crappy 12 point 11 or 12 mm socket on there and apply presssure and righty tighty lefty looesy exept the carb needle

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a 12 point will work the best or use a 8 point if u use a 6 u risk not being able to get it off ever and never use a oem ****ty bolt on these bikes always use genuine stock parts and then u can modify them if you need and still have the old one

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nonononononodisbeliefdisbeliefdisbeliefdisbeliefdisbeliefdisbeliefdisbelieffuriousdohdohdohgod i hate oem parts for this thing



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So I bought the Raid. Running condition. I'm happy, it stil rides nice and solid. I'm quite surprised the about the difference between the OE and the raid.  The raid is much lower. ad_0_1499017436505.jpg



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Nice looking bike Shaunsmile



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Thanks buddy, I'm stoked. Actually bought the bike for my brother. We are planning a weekend trip thru the Baviaans mountain range here in SA during September. You should Google it, it's a awesome stretch of dirt road.  from there he wil take the bike back up to Cape Town  to his house. Drove the raid for about 50km tonight and it never skipped a beat, so I'll take that as good news for now. First need to sort out the OE before I'm lifting a spanner to work on the raid. 



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Hi Shaun

Actually came here to tell you that I have found a TTR in good shape (well, from what I can see) - pretty much stock standard - just seems to be missing the left grab handle.  Funnily enough, mine also was also stock apart from missing that same grab handle?!  confuse

But see you now got a Raid for your brother ... he must be so stoked, going to be epic doing the Baviaans together.  You guys also coming through Die Hel?  
See that the Swartberg Pass was closed on the Prince Albert side due to flooding - can still get through on a bike off course.  

Anyway, here is the bike:
https://www.gumtree.co.za/a-motorcycles-scooters/george/2004-yamaha-ttr-250/1002022956360910936245309

Trying to convince a buddy to buy the bike now - but he is extremely slow on the uptake into the biking fraternity. 

The build is coming along nicely, well done!  Will remember the Rust-Oleum tip.    



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Hey Bud, i have been living on Gumtree the last couple of weeks, and for some or other reason I did not see this one advertised! disbelief, I would have bought it! 

The Raid I bought was advertised for 19K, i managed to bring it down to 14K after highlighting some issues, owner believed the Raid was a 2011 model.  One thing that I have noticed is that both the OE and Raid does not VIN plates on the frame, is there a reason for this? Or is it just on a hidden spot? 

Yes, we are stoked to do the trip. Will be going thru "Die Hell" as well.  We are in a huge drought, so  the road should be open by now. Our planned trip is only later this year.  I wil also be leaving my bike it Cape town then for a later trip back down to PE. 

When im done with my bike, i will clean up the Rais as well, the previous owner spray painted the nice purple rims black.....and its peeling off badly, so ill just get that off. Should be easy. 

Better Pic of the Raid in my Garage, Please excuse the condition of the floor, need to sort that out, but that is a project on its own...  

20170705_065859.jpg

 

 

 



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She is looking good - but seeing those purple rims again will make all the difference!  Really love the round headlight of the Raid ... looks the business.  

Here is a photo from early June showing the Swartberg Pass condition currently after the floods - so bikes can get through, but it is closed for cars.  

Swartberg Pass.JPG

And this one showing the road completed washed out - and location of the wash-out stated.

Swartberg donga.JPG 

So yes, no issue getting through on the bike - so an even more epic trip!!  :)



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That road looks lekker!

 

I was contemplating on posting the below, Felt like a dumb ass when it happened. I saw all the warnings associated with the removal, but I was a bit impatient when removing my clutch basket, and ended up breaking one of my pins off. disbeliefdisbelief

Luckilly, a good mate of mine has a engineering shop, and we managed to sort it out within about 30min! 

Turned a new pin, threaded it, Machined the mating surface, and tig welded the back.  I believe it is even stronger than before.  

 

Before - Im such a dumbass.disbelief

IMG-20170620-WA0018.jpeg

 

Fixed - Hell yeah! 

IMG-20170626-WA0006.jpg

IMG-20170626-WA0008.jpg



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I would dearly love to have a mate like that!!!

Well done for sorting it out so quickly wink

Brian



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Hi guys.starting with the head assembly. Seated the valves, and got a nice seal when checked with some fuel. 

Wil be fitting new valve stem seals as well. 

No im a bit confused looking at my parts that I layed out. The washer third from top, I'm sure this ain't part of the valve assembly, but for some reason I placed it in the same holder as my other parts from the head. If this doesn't go on the valve, what is it for? I've got the exploded diagram, and it's not shown on there. 

20170809_132335.jpg



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Washers for the cylinder head bolts?



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Hi 

yip, as i went along to fit everything, it became clear it was the head bolt washers. 

Got everything assembled except the clutch.  going to make a clutch tool today, as i dont want the pins breaking of again. no

So far everything went together nicely. Just one valve cap was a bit tight, had to polish the cap a bit to get it to move easily 

 



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ttr250.activeboard.com/t52581925/clutch/

looking thru some clutch assembly builds, I came accros this thread. and I am pretty sure my bike did not have this ball bearing in it when I stripped my bike?

I have never ridden the bike, so I cant say if the clutch was operational or not.

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Easy to lose the ball bearing when stripping an engine as you tend to forget its in there and it rolls out at some point and gets lost on the garage floor no

Best put one in when you rebuild the clutch or it might not work properly plus you might cause some damage without the roller action of the ball bearing between the two rods.

Brian



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I wil do a proper check this afternoon. But i am almost sure it wasnt there. I hope I am wrong. If id did fall onto the floor the chances is good that its been swept up or my Kid used it in his Slingshot.  

My plan was to get the engine back in the bike this weekend and get it started. dont hope a simple thing like this will put me back........

What is the specs of this tiny ball? Can i buy it at a local Bearing shop or is is Yamaha exclusive? 

Got my Timing chain in and cams lined up to the best of my ability.  Chain tensioner still working perfect. 

20170810_191929.jpg



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8.7mm in diameter - you might be able to match it.



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I just Phoned our Local Bearingman.  closest they can match a 8.5mm, Cost = 0.00

 

No Stock, only available on Tuesday. Lets hope mine is stil in my garage

 

 



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Hello Everyone

So this weekend I managed to get some headway with the OE.  Managed to get a 8.5mm ball steel ball from a Autospares shop about 50km away from my home. I was in the area and took a change.  Fitted the 8.5mm ball and looks like it wil work. 

Found a slightly different way of fastening my clucth basket, with the help of a friend and 2.5m of towing strap we managed to achieve a torque of 75nm. Stil a risky move, but it worked!

 Motor was fitted to Bike, clutch adjusted to mark on casing. and carburetor cleaned up. despite it lookign very dirty on the outside, it was in great nick on the inside. So nothing to worry about there. 

20170813_202137.jpg

20170813_182225.jpg20170813_201824.jpg

20170813_122144.jpg



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Good progress!

Clever trick on the clutch holder wink

Your carb has cleaned up well! The casting gets hard deposits on it that don't come off with going through the parts washer or the ultrasonic cleaner. Only the bead blaster seems to shift it. But, as you say, it's what's on the inside that matters biggrin

Looking forward to the next update!

Brian



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No Update on bike today. This weekend was my birthday bash, and my wife made me a cake, see if you guys can understand the hidden meaning illustrated on the cake.... 

 

IMG-20170820-WA0004.jpg

 

That is supposed to be me stuck between getting my bike done, and getting the Kitchen makeover done at the same time. 

 

PS: My stomach inst really that round.....



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