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?

mossproof · mossproof

In rebuilding my 325 into a 350 as it has finally succumbed to the dreaded barrel weep, I have found the 6th gear in the transmission is quite badly pitted on the tooth surface. I know this is an issue with the xt/tt 600 engines (top gear being 5th in these) but didn't realise it was much of a problem on our en...

pug · pug

So Bike was running fine end of last year put away for a bit ok 9 months went to get it out for a trip a month back an Houston we have a problem bike was popping and banging I have cleaned the carb fresh and fresh fuel new carb cables new inlet rubber she's still popping and banging the same and wont rev out it fe...

Ttboof · Ttboof

My ignition pick up has gone open circuit. I've ordered one on ebay that I think I can fit to the existing stator/wiring. Being Chinese if it works I might sell the ttr because I can't trust it Tried to buy a complete stator but apparently not available any more Has anyone got a good fix -- Edited by T...

Susan Parker · Susan Parker

PO55 in pieces again - I do not love this bike - and just to make my life more interesting, one of the exhaust manifold nuts sheared off when I was removing the exhaust pipe. Any advice as to how to remove the stud - I have tried loads of WD40 and heating with the blow torch, but it still wont budge.

Tommy the cat · Tommy the cat

Hey, So 8 ish years ago I had the mess of the decompressor bung leaking so changed it for the aluminium turned bug sold on totally ttrs. Now its leaking again. I havent pulled it out but has anyone else had any issues? O ring need replacing? I was just gonna buy a new one but not for sale now. I changed the bolt...

TTR2501966 · TTR2501966

Hi all, I’ve had my TTR 250 1996 for 10 years . The master cylinder failed a few years ago, with rear brake sticking on, and I replaced it with an aftermarket one. The rear brake started sticking again last week and cracking off the master cylinder high pressure connection didn’t free the rear brake so t...

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...

Tucker250 · Tucker250

Hi was wondering if anyone could help me before I pull any more of my hair out?? I replaced the oil and oil filter on my ttr today all was ok untill I started the bike up after i had finished as I noticed That when I rev the bike oil comes out of the top of the oil filter housing and when I release the revs and she i...

apw99 · apw99

Has anyone found a reasonably priced lithium battery that fits in the TTR tight dimensions? I have a 93 model, I assume the later models have the same dimension carrier 150x90x60, can anyone verify? thank you.

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...

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	21	21419	June 11th by Ttboof
	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	7575	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	29447	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	6831	Jan 3, 2024 by Ttboof
	6th gear wear and solutions (Preview) In rebuilding my 325 into a 350 as it has finally succumbed to the dreaded barrel weep, I have found the 6th gear in the transmission is quite badly pitted on the tooth surface. I know this is an issue with the xt/tt 600 engines (top gear being 5th in these) but didn't realise it was much of a problem on our en...	mossproof	11	206	27m ago by mossproof
	Bike popping and banging (Preview) So Bike was running fine end of last year put away for a bit ok 9 months went to get it out for a trip a month back an Houston we have a problem bike was popping and banging I have cleaned the carb fresh and fresh fuel new carb cables new inlet rubber she's still popping and banging the same and wont rev out it fe...	pug	4	79	yesterday by pug
	replaced ignition pick up (Preview) My ignition pick up has gone open circuit. I've ordered one on ebay that I think I can fit to the existing stator/wiring. Being Chinese if it works I might sell the ttr because I can't trust it Tried to buy a complete stator but apparently not available any more Has anyone got a good fix -- Edited by T...	Ttboof	34	2976	3 days ago by Ttboof
	Exhaust manifold studs. (Preview) PO55 in pieces again - I do not love this bike - and just to make my life more interesting, one of the exhaust manifold nuts sheared off when I was removing the exhaust pipe. Any advice as to how to remove the stud - I have tried loads of WD40 and heating with the blow torch, but it still wont budge.	Susan Parker	4	104	July 23rd by Ttboof
	Decompressor bung (Preview) Hey, So 8 ish years ago I had the mess of the decompressor bung leaking so changed it for the aluminium turned bug sold on totally ttrs. Now its leaking again. I havent pulled it out but has anyone else had any issues? O ring need replacing? I was just gonna buy a new one but not for sale now. I changed the bolt...	Tommy the cat	5	241	July 17th by ttr steve
	Rear brake caliper- Piston swollen?? (Preview) Hi all, I’ve had my TTR 250 1996 for 10 years . The master cylinder failed a few years ago, with rear brake sticking on, and I replaced it with an aftermarket one. The rear brake started sticking again last week and cracking off the master cylinder high pressure connection didn’t free the rear brake so t...	TTR2501966	2	205	July 10th by mossproof
	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	5	207	July 5th by TTRfan
	oil leak from filter housing??? (Preview) Hi was wondering if anyone could help me before I pull any more of my hair out?? I replaced the oil and oil filter on my ttr today all was ok untill I started the bike up after i had finished as I noticed That when I rev the bike oil comes out of the top of the oil filter housing and when I release the revs and she i...	Tucker250	8	1577	June 30th by Ttboof
	Lithium Battery? (Preview) Has anyone found a reasonably priced lithium battery that fits in the TTR tight dimensions? I have a 93 model, I assume the later models have the same dimension carrier 150x90x60, can anyone verify? thank you.	apw99	2	189	June 11th by Ttboof
	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	478	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	243	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	294	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	385	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	286	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	420	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	433	Jan 25, 2026 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	492	Dec 15, 2025 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	637	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	1747	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	485	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	612	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	613	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	550	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	630	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	513	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	529	Oct 10, 2025 by ttr steve
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