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

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?

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...

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...

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

tossworm · tossworm

any body know a good supplier for a timing chain for a 4gy. thanks keith.

locky · locky

Fit or not to fit. Do folk remove them for off roading and bypass it ?

pavlos · pavlos

Hi, i would like to enlighten me in a strange issue : after light signs of cracks on tank cap rubber seal and leakage from the keylock barrel, gas cap of tank was changed on TTR '97. After the change, engine switched on and drive about 200m to garage with tank filled by 1/3. Petrol tap has turned off and bike...

Serj · Serj

I just purchased a 2001 TTR250 in California. Previous owner said it was originally from Colorado and hadn’t been ridden in about 20 years. That being said, anything I should take care of right now? Tires are old so I know I have to take care of that, carb was just cleaned. Also I heard these bikes come in m...

NomadaFirefox · NomadaFirefox

Hi. Lately I hear a strange sound in the engine from my TTR250, it is a model from 2005 with over 30000km. One friend (a mechanic) said how it was probable the timing chain but I am not sure. I will try later put the sound here. Mostly I hear it more when the engine starts and it is not specially hot. If the timi...

Darren · Darren

Spotted this on a TTR sales site in China..does any one know if it will fit and is it an easy fit. It says it's a Piagio oil cooler - about 40 pounds... will it fit - any ideas? Daz

robject33 · robject33

Hi all, My seat is missing all of the foam damper pads from the bottom. This means there is a lot of play in the seat when fitted and it rubs on the petrol tank (to the point that I had to get the tank welded as it had rusted through). Is there any specific type of foam / sponge that I should use to fit new dampers?...

AdamPrinsenGeerligs · AdamPrinsenGeerligs

The gear on my starter motor got shredded. i replaced the sprague clutch, and the 1st gear attached to the starter...a reduction gear...it had some wear too... i put a new starter on there. It still has issues...i am starting to shred this new starter motor. I am wondering if anyone here has dealt with t...

LowInertia · LowInertia

Hi, Apologies for the long post that follows. As the title says, my OE tilts to the right when taking hands off. It does so at all speeds and even when hands on, I still have to sit to the left side of the seat. As it's my only vehicle and I do long distances with it, it is pretty annoying and tiring having to ti...

Gabriel2fifD · Gabriel2fifD

Hi all I have a 1995 TTR250 with what looks like an exhaust from a 1994 and the bolt that holds the exhaust to the frame has gone missing because the thread is worn out, is this easy to repair by welding a nut in its place or could I tap a new thread in if there's enough meat? also can anyone identify this exhaus...

rdchair · rdchair

Hi all . Help please . 🙏 bike was running great trail riding at the weekend . Went to start to move up step in garden and it let out an awfull mechanical clunk . I tried to just turn over with kickstart and it was locked . Rocked bike and kick went down once then locked again . Stripped first cover off , all cogs i...

Gabriel2fifD · Gabriel2fifD

I need to buy a top end gasket kit for my 1995 TTR250 I have an oil leak somewhere is there any brands to stay away from because of bad quality I found one in my country and I see this brand "M.C.S" on eBay but I see other brands online, should I try to find an original Yamaha brand though probably more expensiv...

rdchair · rdchair

Hi any recommendations for someone to replace my valve guides ? Cheers . Uk and north preferred

DanH · DanH

After replacing the rebound bump stop on the rear shock and reassembling it, I noticed while pumping the rear shock up and down I hear a slight squeak and also what sounds like air rushing through a valve. Can anyone kindly tell me if this is a typical noise? The shock damping is fine and I can't discern an...

motofunknerd · motofunknerd

Knowledgable enthusiast semi professional sought. Hi all, I'm looking for a keen amateur or part time semi professional TTR 250 mechanic for work on my engine. A very knowledgeable TTR guy, or lass, that has stripped and rebuilt the engines many times and really knows their way around one. I'm not...

wobbly · wobbly

At last a problem with the TTR, near side fork oil seal badly gone, looks a fairly straight forward job, just wondering best place to get the seals and what oil to use. and anything I should be aware of. thanks.

tripodtiger · tripodtiger

I managed to pull the switch end of the clutch / ignition lockout switch out of the lever assembly. And it wont go back in. Nah, she's stuffed, mate. Is there any method of disabling the clutch lockout? Otherwise, I'll just try & wire in something to hold the pin inside the cable in. Meaning the...

Dudley · Dudley

I am currently building a 2004 TT250R engine but I am not sure what goes in the two holes pointed to in the attached picture. The holes are behind the clutch and the only picture I can find in on the TTR250 website and they look like rubber patches, the top one appears to have a smaller hole in it. My best gues...

Susan Parker · Susan Parker

I am in the process of putting the engine back together, having had the bore de glazed and new piston rings installed: the instructions indicate to fit an 'O' ring on the base of the cylinder and the new gasket below the 'O' ring. Is this correct; it doesn't feel like that will make a good seal! The 'o' ring...

MattPass · MattPass

Hello all. Just wondered if anyone had ever had a problem with a slight leak in the carb when standing and not even running. I think (not sure at all) it may be coming from the lid where you access the diaphragm (photo attached). I took the carb off and then tightened everything up. However, still leaki...

robject33 · robject33

My fuel tank has rusted through from where the seat has been rubbing on it. Previous owner must have left it bare metal like that for quite a while and there are two holes on the one side. I've attacked it with a wire brush attachment and this is the result: What would you all recommend I do to fix this? I h...

Texas · Texas

Just started a couple days ago, noted that my speed was fluttering by up to 20kph, now, wildly. I even saw it at 170kph today which is obviously impossible. Can some wise head advise, is this likely to be the magnet in process of breaking up or the sensor malfunctioning?

MichaeltT · MichaeltT

Good afternoon all i hope you are all well, i have a 2004 blue tanked ttr250 that came to me with LED indicators problem is they don't flash just stay on as a solid amber light has anyone got a link to a relay that is meant for LED winkers, I have tried the old post links but they are not active links anymore. ...

Topic		Started By	Replies	Views	Last Post
	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	6494	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	26140	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	5243	Jan 3, 2024 by Ttboof
	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	18	18420	Dec 2, 2017 by TerryK
	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	0	354	4 days ago by Tommy the cat
	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	259	4 days ago 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	851	11 days ago by mossproof
	timing chain (Preview) any body know a good supplier for a timing chain for a 4gy. thanks keith.	tossworm	21	28413	12 days ago by mmwain
	Side stand switch. (Preview) Fit or not to fit. Do folk remove them for off roading and bypass it ?	locky	7	1582	August 27th by Ttboof
	Tank gas cap leakage tank gas leakage (Preview) Hi, i would like to enlighten me in a strange issue : after light signs of cracks on tank cap rubber seal and leakage from the keylock barrel, gas cap of tank was changed on TTR '97. After the change, engine switched on and drive about 200m to garage with tank filled by 1/3. Petrol tap has turned off and bike...	pavlos	8	1490	August 23rd by Serj
	New to me TTR250 2001 TTR250 Yamaha headlight old (Preview) I just purchased a 2001 TTR250 in California. Previous owner said it was originally from Colorado and hadn’t been ridden in about 20 years. That being said, anything I should take care of right now? Tires are old so I know I have to take care of that, carb was just cleaned. Also I heard these bikes come in m...	Serj	1	435	August 21st by mossproof
	Strange engine sound (Preview) Hi. Lately I hear a strange sound in the engine from my TTR250, it is a model from 2005 with over 30000km. One friend (a mechanic) said how it was probable the timing chain but I am not sure. I will try later put the sound here. Mostly I hear it more when the engine starts and it is not specially hot. If the timi...	NomadaFirefox	3	619	August 19th by NomadaFirefox
	Oil cooler information ( 1 2 3 4 ) (Preview) Spotted this on a TTR sales site in China..does any one know if it will fit and is it an easy fit. It says it's a Piagio oil cooler - about 40 pounds... will it fit - any ideas? Daz	Darren	175	175566	August 13th by mmwain
	Seat repairs (Preview) Hi all, My seat is missing all of the foam damper pads from the bottom. This means there is a lot of play in the seat when fitted and it rubs on the petrol tank (to the point that I had to get the tank welded as it had rusted through). Is there any specific type of foam / sponge that I should use to fit new dampers?...	robject33	0	440	August 5th by robject33
	starter motor getting shredded (Preview) The gear on my starter motor got shredded. i replaced the sprague clutch, and the 1st gear attached to the starter...a reduction gear...it had some wear too... i put a new starter on there. It still has issues...i am starting to shred this new starter motor. I am wondering if anyone here has dealt with t...	AdamPrinsenGeerligs	6	513	July 31st by ttr steve
	Bike tilting to the right when taking hands off (Preview) Hi, Apologies for the long post that follows. As the title says, my OE tilts to the right when taking hands off. It does so at all speeds and even when hands on, I still have to sit to the left side of the seat. As it's my only vehicle and I do long distances with it, it is pretty annoying and tiring having to ti...	LowInertia	3	530	July 28th by Ttboof
	Exhaust bolt has no thread any more (Preview) Hi all I have a 1995 TTR250 with what looks like an exhaust from a 1994 and the bolt that holds the exhaust to the frame has gone missing because the thread is worn out, is this easy to repair by welding a nut in its place or could I tap a new thread in if there's enough meat? also can anyone identify this exhaus...	Gabriel2fifD	2	602	June 8th by Gabriel2fifD
	Dreaded clunk . Plus kickstart locking up engine . (Preview) Hi all . Help please . 🙏 bike was running great trail riding at the weekend . Went to start to move up step in garden and it let out an awfull mechanical clunk . I tried to just turn over with kickstart and it was locked . Rocked bike and kick went down once then locked again . Stripped first cover off , all cogs i...	rdchair	19	846	May 30th by rdchair
	A good brand for a top end gasket kit (Preview) I need to buy a top end gasket kit for my 1995 TTR250 I have an oil leak somewhere is there any brands to stay away from because of bad quality I found one in my country and I see this brand "M.C.S" on eBay but I see other brands online, should I try to find an original Yamaha brand though probably more expensiv...	Gabriel2fifD	0	171	May 28th by Gabriel2fifD
	Valve guides replacement specialist (Preview) Hi any recommendations for someone to replace my valve guides ? Cheers . Uk and north preferred	rdchair	2	574	May 27th by rdchair
	Rear Shock Noise- Is this normal for a TTR? (Preview) After replacing the rebound bump stop on the rear shock and reassembling it, I noticed while pumping the rear shock up and down I hear a slight squeak and also what sounds like air rushing through a valve. Can anyone kindly tell me if this is a typical noise? The shock damping is fine and I can't discern an...	DanH	8	668	May 25th by JOHNYBOY
	Knowledgable enthusiast semi professional sought (Preview) Knowledgable enthusiast semi professional sought. Hi all, I'm looking for a keen amateur or part time semi professional TTR 250 mechanic for work on my engine. A very knowledgeable TTR guy, or lass, that has stripped and rebuilt the engines many times and really knows their way around one. I'm not...	motofunknerd	4	560	May 24th by motofunknerd
	Fork seals (Preview) At last a problem with the TTR, near side fork oil seal badly gone, looks a fairly straight forward job, just wondering best place to get the seals and what oil to use. and anything I should be aware of. thanks.	wobbly	8	790	May 23rd by tripodtiger
	Clutch / ignition lockout switch disabling? (Preview) I managed to pull the switch end of the clutch / ignition lockout switch out of the lever assembly. And it wont go back in. Nah, she's stuffed, mate. Is there any method of disabling the clutch lockout? Otherwise, I'll just try & wire in something to hold the pin inside the cable in. Meaning the...	tripodtiger	5	586	May 23rd by tripodtiger
	identification help please (Preview) I am currently building a 2004 TT250R engine but I am not sure what goes in the two holes pointed to in the attached picture. The holes are behind the clutch and the only picture I can find in on the TTR250 website and they look like rubber patches, the top one appears to have a smaller hole in it. My best gues...	Dudley	6	446	May 16th by tripodtiger
	Continuing saga of PO55 (Preview) I am in the process of putting the engine back together, having had the bore de glazed and new piston rings installed: the instructions indicate to fit an 'O' ring on the base of the cylinder and the new gasket below the 'O' ring. Is this correct; it doesn't feel like that will make a good seal! The 'o' ring...	Susan Parker	7	604	May 5th by Susan Parker
	Carb slightly leaking (Preview) Hello all. Just wondered if anyone had ever had a problem with a slight leak in the carb when standing and not even running. I think (not sure at all) it may be coming from the lid where you access the diaphragm (photo attached). I took the carb off and then tightened everything up. However, still leaki...	MattPass	4	699	April 20th by ttr steve
	Rusted fuel tank (Preview) My fuel tank has rusted through from where the seat has been rubbing on it. Previous owner must have left it bare metal like that for quite a while and there are two holes on the one side. I've attacked it with a wire brush attachment and this is the result: What would you all recommend I do to fix this? I h...	robject33	2	551	April 10th by robject33
	Speed indication wildly fluttering RAID magnet or sensor? (Preview) Just started a couple days ago, noted that my speed was fluttering by up to 20kph, now, wildly. I even saw it at 170kph today which is obviously impossible. Can some wise head advise, is this likely to be the magnet in process of breaking up or the sensor malfunctioning?	Texas	1	620	April 4th by ttr steve
	LED indicator flasher relay 2004 blue tank (Preview) Good afternoon all i hope you are all well, i have a 2004 blue tanked ttr250 that came to me with LED indicators problem is they don't flash just stay on as a solid amber light has anyone got a link to a relay that is meant for LED winkers, I have tried the old post links but they are not active links anymore. ...	MichaeltT	3	954	April 1st by Texas
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