A forum for owners of Yamaha TTR250 trail and enduro bikes!

kylarama · kylarama

Years ago when I last went riding I used to fill up my backpack with all types of useless crap that was heavy and probably only usefull on everyone elses bikes. What basic tools and spares specifically suited to a TTR should I carry as a minimum? Generally we wouldn't venture anymore than about 100km...

TTRfan · TTRfan

As suggested by brindabella, I have started this thread to show my own choice of "proven/economical/useful workshop consumables". I have started off with my UK thoughts maybe other owners from USA, Australia, etc, can weigh in with their local equivalent brands...... First off, one o...

TTRfan · TTRfan

Thread repair kits. These have got me out of trouble on a regular basis! Available quite cheaply on eBay. For the manufacturer's page - see here

Forgorin · Forgorin

So, I'm looking for more power! I have a '94 raid. I am hoping to add electric grips and an electric vest. Grips run at about 60 watts. That's almost half of what the stator produces. Are there any aftermarket stators for the bike? Am I looking at a rebuild?

Brighton Brad · Brighton Brad

Hi kids, does anyone have some pics of the wiring loom routing, I’ve a workshop manual, but I’m still struggling!! I’ve had the frame powder coated and of course didn’t take any pics before disassemblage 🫣 lesson learnt. . . maybe!! Any pics most appreciate, need to get it back together asap 🙏 ps is a rai...

IOWChris · IOWChris

Just rebuilding parts of my 350 while I wait for a bolt to turn up and tried getting the exhaust on Im sure I’m being stupid here but I can’t see what I’m missing. The header doesn’t go on, not even close! The silencer end only goes through the frame in one orientation and that lands the head end jammed into t...

Maxwellstorm · Maxwellstorm

hey all trying to diagnose a no spark issue I did accidentally blow up the ignition coil trying to do a bench test on it so a new one is on the way however after checking a few things i'm not so sure the coil was ever the issue few things I found: voltage at the orange wire going into coil is consistently readi...

apw99 · apw99

Hi, my 1993 TTR was ticking over and suddenly cut out with a loud bang. It is now dead and the starter button makes no sound on activation. I put it in gear and rocked it to free up the sprag clutch in case it was stuck but no joy. The starter has always had a recoil sound after starting, I've had the bike at lea...

dr268 · dr268

took the carb off and the inlet rubber has delaminated question is, are any of the after market inlet rubbers any good or should i stick with genuine ? I see some pretty nasty looking ones at less than £10 and have no interest but I see some at approx £30 that look as if they are actually made of rubber and cou...

dr268 · dr268

is there an alternative to the Yamaha shock protection flap on a 03 TTR250 ? There are plenty listed but am unsure if any of them fit or could be modified to fit thanks

IOWChris · IOWChris

Fitting my 350 kit and have just started reassembling. I’ve pressed the crankshaft into the bearing using the flywheel bolt and a socket per the suggestion in the excellent guide but the teeth on the crank are sitting slightly higher than the balancer teeth The picture I took before taking apart doe...

JonScott · JonScott

I measured my barrel with a bore gauge. It's out of round by about 0.003 (3 thou) Google says it's time for a rebore, would everyone here agree? Would .5mm be enough? Would anyone like to recommend a machine shop, either that I can post to, or that's in the Didcot (S.Oxon.) area? Thanks in advance. Jon....

Ttboof · Ttboof

Ive been putting it off for ages but repacked the steering head bearings today . 40 deg in the shed so a bit of a chore lol but it good to have it done

Serj · Serj

I have a 2002 TTR250, starts up fine but when I give it throttle and the rpms settle down, it does this weird vibration/rattling like it has an air leak and the rpms kinda go up a little. Anyone experienced this before? Here is a link to a video I took. https://share.icloud.com/photos/03dsY_k6vXv6i-...

The Drifter · The Drifter

can anyone help i changed my front tyre on my ttr 250 and i have over tightened one of the axle holder bolts [10mm] which caused it to shear [im gutted] and i think they are welded to the fork as anyone got any suggestions on my options without great expense.

Browncow · Browncow

New to me, ive just got a 2003 yamaha ttr250 , when you put a fully charged up battery connected and try the starter all i here is a slight click, i wondered what to look at to fix , this, the compression seems low when turning the engine over on the kickstarter with the spark plug in, its done under a 1000 mile...

mossproof · mossproof

Had a new issue this weekend that I've not come across before. Thought I'd share it: For some time now, my neutral light has glowed dimly whatever gear I was in, in wet weather. Came on brightly in neutral as normal. I just assumed it was damp causing a mild short across the neutral switch which is freque...

Gabriel2fifD · Gabriel2fifD

I have found an oil leak coming from the left side of the bolt and copper washer from the top oil delivery pipe I've looked in the service manual and it says: oil delivery pipe union bolt M10 x2 20Nm oil delivery pipe union bolt M8 x1 18Nm but my bolts are 14mm x1 top bolt and 12mm x2 lower bolts, should I stil...

Gabriel2fifD · Gabriel2fifD

I just got a compression tester and my bike has a reading of 200 psi with the throttle open and a cold test it feels a bit sluggish so I'm looking into checking valve clearances, from memory the manual says 175 psi is standard so I'm wondering how is mine 200 psi. My tester has schrader valves in the hose at t...

Gabriel2fifD · Gabriel2fifD

Before I put my 1995 TTR250 Open Enduro on the road I am going to replace the following parts: Timing Chain = 945-91431-22-00 chain guide (exhaust side) = 4GY-12251-00-00 chain guide (intake side) = 4GY-12252-00-00 Piston (Standard) = 4GY-11631-00-C0 Piston Rings (Standard) = 4GY-11603-00-...

mro · mro

Hi all,just wondering if anyone has had there TTR250 at 6000 kms or higher,and have performed a valve clearance check,and found their clearances have not needed adjusting?Or if your valve clearanes were out,what were the signs that made you inspect them? If your valves are not in tolerance,will it...

MobileMedic67 · MobileMedic67

Hello all, hoping to get some info from the experts on the forum So, I purchased a 1994 TTR250 Raid around 3 weeks ago, rode it home on the day I bought it (around 85 miles) and the speedo and odometer was working perfectly, it was placed in my garage so I could check it over in my own time, I removed the batter...

JonScott · JonScott

Hi all, introduced myself a few weeks ago, as yet to buy my first TTR250. Since then I got myself a '93 OE. No pictures yet, but, you know what they look like right? Seems fairly stock apart from the Red bark-buster type grip guards. The bike seems in pretty good order, with the following list to fettle (...

Rossyboys · Rossyboys

I have a problem with Spark. (It only sparks for less than a second ) I have removed the spark plug and left the spark plug lead on and press start, the motor turns over however the spark only last a second then nothing as the motor cranks over. If I try again nothing. However if I let it sit for ten minutes...

MobileMedic67 · MobileMedic67

Hello, I'm a new owner of a 1993/94 TTR250 Raid, I've decided to change the front fork oil and noticed on stripping the fork legs down that there is no internal damper rod connected to the fork cap, is this normal ? Been looking for a workshop manual that covers this bike but they seem to be hard to find ?

New Owner/New Member Carb issues · digithead

HELLO ALL! Found you via Google. Im 67 and riding since about 10 years old. Started on those Honda 50 and 70's we all love. Got a used 2003 TTR250 for $1400usd. When I went to get it he agreed it had a idle problem. Would stall if you didnt hold a little gas on. But other then that rode and ran great and shifte...

Tommy the cat · Tommy the cat

Hey all, just getting back into riding after far too long away. I want/ need to do some jobs on the old girl but would like a paper manual.... Ive got the computer version off Brian but find it a pain. My question is.... was the 1998 a weird year or something as all the manuals ( Hayes and clymer) don't come up...

Joss · Joss

Is there a replacement cable or one off another model that will fit ? I can find new ones but they say I'll need to wait 14 days ,and I need one for the weekend as I'm doing a long distance trail on Sunday.

Tommy the cat · Tommy the cat

So I've just changed a leaking fork seal and refreshed with new oil. Now we nipped up the 14mm base valve nut at the bottom of the forks with the idea of fully tightening when the fork is back on the bike. We can't get the nut to tighten and it sounds like somethings spinning inside to fork. So a bit of digging...

Tommy the cat · Tommy the cat

So a simple (ish ) job has become a nightmare! I was torquing the lower pinch bolts up to spec and was just thinking wow that's tight and snap doh. Any advice how to remove and where to get said bolt? Its the lower yoke pinch bolt top bolt ( caliper side. I cant seem to upload a photo? D

Topic		Started By	Replies	Views	Last Post
	STICKY: Basic tool kit & spares. What to carry on a ride? (Preview) Years ago when I last went riding I used to fill up my backpack with all types of useless crap that was heavy and probably only usefull on everyone elses bikes. What basic tools and spares specifically suited to a TTR should I carry as a minimum? Generally we wouldn't venture anymore than about 100km...	kylarama	20	20903	8h ago by AussieChookchaser
	STICKY: Essential workshop consumables - my choice - UK products (Preview) As suggested by brindabella, I have started this thread to show my own choice of "proven/economical/useful workshop consumables". I have started off with my UK thoughts maybe other owners from USA, Australia, etc, can weigh in with their local equivalent brands...... First off, one o...	TTRfan	8	7471	Mar 10, 2024 by TTRfan
	STICKY: Essential workshop tools! Please add yours to the thread... (Preview) Thread repair kits. These have got me out of trouble on a regular basis! Available quite cheaply on eBay. For the manufacturer's page - see here	TTRfan	30	28904	Jan 22, 2024 by Ttboof
	STICKY: Output of stator (AC magneto generator) and wattage used by bulbs, etc. (Preview) So, I'm looking for more power! I have a '94 raid. I am hoping to add electric grips and an electric vest. Grips run at about 60 watts. That's almost half of what the stator produces. Are there any aftermarket stators for the bike? Am I looking at a rebuild?	Forgorin	10	6647	Jan 3, 2024 by Ttboof
	Wiring Loom Routing!! (Preview) Hi kids, does anyone have some pics of the wiring loom routing, I’ve a workshop manual, but I’m still struggling!! I’ve had the frame powder coated and of course didn’t take any pics before disassemblage 🫣 lesson learnt. . . maybe!! Any pics most appreciate, need to get it back together asap 🙏 ps is a rai...	Brighton Brad	0	6	2h ago by Brighton Brad
	Fitting exhaust header (Preview) Just rebuilding parts of my 350 while I wait for a bolt to turn up and tried getting the exhaust on Im sure I’m being stupid here but I can’t see what I’m missing. The header doesn’t go on, not even close! The silencer end only goes through the frame in one orientation and that lands the head end jammed into t...	IOWChris	5	258	May 16th by TTRfan
	No spark no spark spakr plug ignition (Preview) hey all trying to diagnose a no spark issue I did accidentally blow up the ignition coil trying to do a bench test on it so a new one is on the way however after checking a few things i'm not so sure the coil was ever the issue few things I found: voltage at the orange wire going into coil is consistently readi...	Maxwellstorm	1	144	May 13th by TTRfan
	Bike cut out with a loud bang (Preview) Hi, my 1993 TTR was ticking over and suddenly cut out with a loud bang. It is now dead and the starter button makes no sound on activation. I put it in gear and rocked it to free up the sprag clutch in case it was stuck but no joy. The starter has always had a recoil sound after starting, I've had the bike at lea...	apw99	2	190	April 27th by apw99
	inlet rubber advice required (Preview) took the carb off and the inlet rubber has delaminated question is, are any of the after market inlet rubbers any good or should i stick with genuine ? I see some pretty nasty looking ones at less than £10 and have no interest but I see some at approx £30 that look as if they are actually made of rubber and cou...	dr268	3	291	March 31st by JOHNYBOY
	Rear shock flap alternative ? (Preview) is there an alternative to the Yamaha shock protection flap on a 03 TTR250 ? There are plenty listed but am unsure if any of them fit or could be modified to fit thanks	dr268	1	203	March 17th by Ttboof
	Pulling crank into main bearing (Preview) Fitting my 350 kit and have just started reassembling. I’ve pressed the crankshaft into the bearing using the flywheel bolt and a socket per the suggestion in the excellent guide but the teeth on the crank are sitting slightly higher than the balancer teeth The picture I took before taking apart doe...	IOWChris	6	344	February 12th by ttr steve
	Is it time for a rebore? (tolerances) (Preview) I measured my barrel with a bore gauge. It's out of round by about 0.003 (3 thou) Google says it's time for a rebore, would everyone here agree? Would .5mm be enough? Would anyone like to recommend a machine shop, either that I can post to, or that's in the Didcot (S.Oxon.) area? Thanks in advance. Jon....	JonScott	5	340	January 25th by mossproof
	Lubed the head bearings (Preview) Ive been putting it off for ages but repacked the steering head bearings today . 40 deg in the shed so a bit of a chore lol but it good to have it done	Ttboof	4	398	December 15th by Ttboof
	Possible air leak Idle rpm leak carb (Preview) I have a 2002 TTR250, starts up fine but when I give it throttle and the rpms settle down, it does this weird vibration/rattling like it has an air leak and the rpms kinda go up a little. Anyone experienced this before? Here is a link to a video I took. https://share.icloud.com/photos/03dsY_k6vXv6i-...	Serj	2	400	Dec 7, 2025 by Ttboof
	Front Fork clamp bolt sheared !!! (Preview) can anyone help i changed my front tyre on my ttr 250 and i have over tightened one of the axle holder bolts [10mm] which caused it to shear [im gutted] and i think they are welded to the fork as anyone got any suggestions on my options without great expense.	The Drifter	13	1632	Dec 5, 2025 by AussieChookchaser
	2003 yamaha ttr250, when battery fully charged, starter just makes a click noise (Preview) New to me, ive just got a 2003 yamaha ttr250 , when you put a fully charged up battery connected and try the starter all i here is a slight click, i wondered what to look at to fix , this, the compression seems low when turning the engine over on the kickstarter with the spark plug in, its done under a 1000 mile...	Browncow	1	400	Nov 26, 2025 by Ttboof
	Neutral light and the diode (Preview) Had a new issue this weekend that I've not come across before. Thought I'd share it: For some time now, my neutral light has glowed dimly whatever gear I was in, in wet weather. Came on brightly in neutral as normal. I just assumed it was damp causing a mild short across the neutral switch which is freque...	mossproof	4	502	Nov 24, 2025 by TTRfan
	Torque setting for Oil Delivery Pipe (Preview) I have found an oil leak coming from the left side of the bolt and copper washer from the top oil delivery pipe I've looked in the service manual and it says: oil delivery pipe union bolt M10 x2 20Nm oil delivery pipe union bolt M8 x1 18Nm but my bolts are 14mm x1 top bolt and 12mm x2 lower bolts, should I stil...	Gabriel2fifD	5	487	Nov 3, 2025 by TTRfan
	What is a good psi compression reading (Preview) I just got a compression tester and my bike has a reading of 200 psi with the throttle open and a cold test it feels a bit sluggish so I'm looking into checking valve clearances, from memory the manual says 175 psi is standard so I'm wondering how is mine 200 psi. My tester has schrader valves in the hose at t...	Gabriel2fifD	0	472	Oct 24, 2025 by Gabriel2fifD
	Should I get OEM or aftermarket for timing chain, chain guides, Piston and rings (Preview) Before I put my 1995 TTR250 Open Enduro on the road I am going to replace the following parts: Timing Chain = 945-91431-22-00 chain guide (exhaust side) = 4GY-12251-00-00 chain guide (intake side) = 4GY-12252-00-00 Piston (Standard) = 4GY-11631-00-C0 Piston Rings (Standard) = 4GY-11603-00-...	Gabriel2fifD	3	528	Oct 18, 2025 by mozzy
	Valve clearances (Preview) Hi all,just wondering if anyone has had there TTR250 at 6000 kms or higher,and have performed a valve clearance check,and found their clearances have not needed adjusting?Or if your valve clearanes were out,what were the signs that made you inspect them? If your valves are not in tolerance,will it...	mro	0	418	Oct 12, 2025 by mro
	TTR250 Raid Digital Speedo ? (Preview) Hello all, hoping to get some info from the experts on the forum So, I purchased a 1994 TTR250 Raid around 3 weeks ago, rode it home on the day I bought it (around 85 miles) and the speedo and odometer was working perfectly, it was placed in my garage so I could check it over in my own time, I removed the batter...	MobileMedic67	1	451	Oct 10, 2025 by ttr steve
	New TTR - Issue list (Preview) Hi all, introduced myself a few weeks ago, as yet to buy my first TTR250. Since then I got myself a '93 OE. No pictures yet, but, you know what they look like right? Seems fairly stock apart from the Red bark-buster type grip guards. The bike seems in pretty good order, with the following list to fettle (...	JonScott	0	513	Oct 7, 2025 by JonScott
	Engine turns over, but sparks for a few spark flashes then nothing as motor turns over (Preview) I have a problem with Spark. (It only sparks for less than a second ) I have removed the spark plug and left the spark plug lead on and press start, the motor turns over however the spark only last a second then nothing as the motor cranks over. If I try again nothing. However if I let it sit for ten minutes...	Rossyboys	6	526	Oct 4, 2025 by Rossyboys
	TTR250 Raid Front Forks (Preview) Hello, I'm a new owner of a 1993/94 TTR250 Raid, I've decided to change the front fork oil and noticed on stripping the fork legs down that there is no internal damper rod connected to the fork cap, is this normal ? Been looking for a workshop manual that covers this bike but they seem to be hard to find ?	MobileMedic67	2	621	Sep 29, 2025 by mossproof
	New Owner/New Member Carb issues Carb Coughing Bucking (Preview) HELLO ALL! Found you via Google. Im 67 and riding since about 10 years old. Started on those Honda 50 and 70's we all love. Got a used 2003 TTR250 for $1400usd. When I went to get it he agreed it had a idle problem. Would stall if you didnt hold a little gas on. But other then that rode and ran great and shifte...	digithead	3	1151	Sep 22, 2025 by Ttboof
	Paper manual for 1998 ttr250 (Preview) Hey all, just getting back into riding after far too long away. I want/ need to do some jobs on the old girl but would like a paper manual.... Ive got the computer version off Brian but find it a pain. My question is.... was the 1998 a weird year or something as all the manuals ( Hayes and clymer) don't come up...	Tommy the cat	1	1324	Sep 21, 2025 by TTRfan
	2003 Speedo cable ? (Preview) Is there a replacement cable or one off another model that will fit ? I can find new ones but they say I'll need to wait 14 days ,and I need one for the weekend as I'm doing a long distance trail on Sunday.	Joss	1	1202	Sep 15, 2025 by Ttboof
	Fork base valve tightening (Preview) So I've just changed a leaking fork seal and refreshed with new oil. Now we nipped up the 14mm base valve nut at the bottom of the forks with the idea of fully tightening when the fork is back on the bike. We can't get the nut to tighten and it sounds like somethings spinning inside to fork. So a bit of digging...	Tommy the cat	2	1028	Sep 9, 2025 by Tommy the cat
	Snapped pinch bolt lower yoke.... (Preview) So a simple (ish ) job has become a nightmare! I was torquing the lower pinch bolts up to spec and was just thinking wow that's tight and snap doh. Any advice how to remove and where to get said bolt? Its the lower yoke pinch bolt top bolt ( caliper side. I cant seem to upload a photo? D	Tommy the cat	4	1615	Sep 1, 2025 by mossproof
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