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Ttr250 rebuild progress
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Here’s my ttr250 

it’s not going to look brand new just to make it a good usable bike that I’m not going to be afraid to use, here’s a couple pics

so far 

frames been sandblasted and powdercoated black

head stock greased and re assembled 

swinging arm grease and put on 

next job is to put new top and bottom bearings in the rear shock

 



-- Edited by Martinm on Sunday 3rd of June 2018 03:08:13 PM

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Looks good so farsmilesmile



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That frame is a great base to work from biggrin



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Hey Martin, I'm really interested in this because at some point I'd like to take mine to pieces to get the frame powder coated.

Does anyone know if there are any tutorials or videos or anything about how to do this, or would the service/owner manuals be the best reference for a task like this?

Cheers,

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One tip I’ve seen on here before powder coating is to mask up frame numbers before hand other wise you will not be able to see them like mine 🤭 alway learn something new after you have done the job, does any one no how to make them re appear???
Not shore about any guidance videos I’ve only just joined the group I’m shore there are and I’m shore someone will point you in the right direction 👍

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See http://ttr250.activeboard.com/t63813609/powder-coating-information-preparing-frame-powder-coating-v-/



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Thanks TTRfan!

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1.jpeg

 



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2.jpeg

3.jpeg

4.jpeg

5.jpeg

 



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Just doing the wiring and I could do with some help I have put some pictures up can anyone tell me what goes where? 🤔🤔🤔

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It all starts to make sense when the engine's back in!

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I am at the same point and have the same dilemma, got carried away on the strip down and ended up taking it back to a bare frame and staying. I a now putting it back together and realised I didn’t take enough photos to identify the routing or where everything goes!

I have loads of brackets and clips that could go anywhere, need to clean up the loom and hoping once that on it will help identify the positions better, however, some bits I took off after the engine was out, not sure on access if I put it back in beforehand?

If you find anything useful can you let me know?

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Any of these photos help?  I have printed these two and laminated them to use in frame-up rebuilds.

Under the tank pics 001.jpg

Under the tank pics 002.jpg



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This photo shows the wires, terminals and clips around the shock reservoir:

Engine mount - top rear.jpg

 

These photos show how I fit the loom and clips before fitting the swingarm and mill.

Build progress 1.jpg

Build progress 7.jpg

Build progress 6.jpg

Build progress 015.jpg

 

After fitting swingarm:

Build progress 021.jpg

 

There is quite a good routing diagram in the workshop manual - see https://estore-sslserver.eu/totallyttrs.com/epages/699105d9-e4cc-4b32-b236-84e72cd67f84.sf/en_GB/?ObjectPath=/Shops/699105d9-e4cc-4b32-b236-84e72cd67f84/Products/TTR-0034

There might also be helpful photos if you look at some of the restoration threads on here.

If you are still stuck, let us know specifically which cable/connectors and I am sure we can help!

Brian



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Dale I feel your pain I brought my bike in a pile of bits so I’m guessing everything but it all seems to be going back together ok so far, hopefully the pictures that Brian has put up help you as well,

Thanks Brian for the pictures they are a grate help and thanks for the service manual link I have downloaded it and currently printing it off.
Also like to thank Steve for the manual and helping me sort it out I’m rubbish with computers but I have got it sorted 👍👍👍



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Happy to help matey and as you are just up the road, you are welcome to pop by for some help/ teasmile



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Brian you are a legend! Photos are fantastic, I have the Haynes manual in the garage which hasn’t been much help but remembered I had purchased the manual already from Totally TTRs, (must print it out for garage use!) it’s a bit better but it isn’t as comprehensive as the photos :)



-- Edited by Sponger on Saturday 21st of July 2018 03:43:32 PM

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B5B0DE58-A47F-435A-81D4-068F5E5165AD.jpeg9D50157F-C170-4801-8E8E-9540C1ECB487.jpeg

29EA462E-08CD-41D7-AA81-C27B984CC125.jpeg



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Started stripping engine down to day and this is what I found, what would you guys do now coz there are bits missing and I can only imagine there in the bottom end I didn’t really want to split bottom end as I think it’s abit out of my depth and recommendations welcome

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Hi Martyn. That is a real downer and such a shame when your rebuild was looking so promising no

I am afraid you are going to have to split the crankcases to see what's happened down below. At the very least you should have some biggish lumps of metal to extract!

I can honestly say that it sounds more difficult and scary to do than it actually is.

You have to be methodical, take lots of photos as it's your first time so that you have a visual clue as to what goes back where, and if you are unsure of a procedure at any time then stop and ask us for help wink

This guide may help you decide whether to tackle the job. 

Does the cylinder head and valve gear look OK?

Take the piston off and check the big and little ends on the crankshaft.

My guess (hope) is that the TTR would have stopped fairly abruptly when it seized and there shouldn't be too much collateral damage with metal swarf being carried around the engine. 

The big question is  - why did it seize? If it was lack of oil then the main parts to suffer are big and little ends and the camshaft assembly - particularly the camshaft journals and where they run in the head. 

At the very least you will be looking for a replacement barrel and piston and I see that Steve has a kit in the shop ready to go - see here

A cheap replacement crankshaft should you need it is also in the shop here

Don't hesitate to ask any further questions!

Brian

 



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Ouch! cry

Typically there was a barrel and piston on eBay the other day, went for £30 + £10 postage!

Hope there is nothing too terminal if you do go for it and split the case.



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The head and valves All look ok and before stripping it was turning over freely. Here’s where I have got to now thought I may as well strip the hole lot 🙃88425A98-820F-4D8C-87DC-705DB41BD0C4.jpeg2CD482E2-04A6-48D2-9109-D8716A55411D.jpeg



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Has anybody got any tips on remove this bolt?9A5DD974-C2DE-4F10-89DB-D84B412B9C56.jpeg



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Ideally you would use a windy gun.

You may be able to get an adjustable on the flats of the flywheel boss to hold the flywheel whilst you undo the bolt with a socket.

Flywheel_nut_removal.jpg

I used to use a ground down pipe wrench which has a 90 degree bend - ground down to fit the flats.

Flywheel_bolt.JPG

Brian

 



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Ideal Brian I’ll give that ago tomorrow, didn’t see that, that should work a treat

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I am pleased that you are having a go Martin - good on you biggrin

Just a hint - watch out for thrust washers such as the one behind the wide need bearing on Gear 3. All too easy to miss them both on the dismantling and the rebuild!

Brian



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Thanks for your advice Brian worked a treat here’s what I have found worth taking apart I think😉.

i have 1 ball bearing that fell out and have no idea where it goes as and the bearings seem to be compleate 

95F5B5E0-0540-4D27-A8B1-7400D5CF44BB.jpeg

Worked a treat Brian th51FACBFE-3AFE-4A81-A43F-13CA566B27BB.jpeg3869E64D-34C2-481F-95E4-1B530DA429D4.jpegF98A3EEB-717D-40B2-A4D2-071BDBF0B4B5.jpeg



-- Edited by Martinm on Sunday 22nd of July 2018 02:04:10 PM

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I can't see any obvious internal damage from the photos. What does it look like to you?

The ball bearing is almost certainly part 28 in the diagram below wink   (Ignore the red arrow!)

clutch_lock_washer.jpg



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All looks good to me now all the bits are out doesn’t seem to be any damage,


And that’s the beauty ball bearing part 28 👌 makes sense now




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This is a great thread Martin, I'm glad you got your problem sorted and looking forward to seeing the rest of the build.

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Holy smoke!!! Not tuned in for a few days and just seen this! Cripes never seen one like that before, how did it happen?????



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Hi Steve that’s what I thought when I seen what had happened in side,I havent A clue what happened to it, I brought bike in pieces (kit form) with engine complete but out of the frame I got told possible valve stuck from the person I brought it off,so I stripped it down to find this mess, 😂

she will run again in future 🤔hopefully 



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Good on you for fixing her up, we are all here to help if needed.



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Great post..such a wealth of info and experience...as are all of the posts on here....nice to know .. and see ..... a picture saves much head scratching..

I was half expecting your next post to show the machined crankcase ready for the new 350 barrel....... all exciting stuff... cant wait......! it cant be that far away....? fingers crossed

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Where do you buy the 350 cylinder from and how much does it cost 



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The 350 is not yet available to buy, we have 2 of them that are about to be road tested.



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Awesome work so far!

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