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...

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

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

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	7224	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	27780	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	6235	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	19938	Dec 2, 2017 by TerryK
	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	168	13 days ago 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	153	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	207	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	198	December 7th 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	1434	December 5th 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	211	November 26th 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	304	November 24th 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	299	November 3rd 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	263	October 24th 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	281	October 18th 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	228	October 12th 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	246	October 10th 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	320	October 7th 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	350	October 4th 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	439	September 29th 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	959	September 22nd 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	1141	September 21st 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	1016	September 15th 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	854	September 9th 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	1421	September 1st by mossproof
	timing chain (Preview) any body know a good supplier for a timing chain for a 4gy. thanks keith.	tossworm	21	29932	August 31st by mmwain
	Side stand switch. (Preview) Fit or not to fit. Do folk remove them for off roading and bypass it ?	locky	7	2199	Aug 27, 2025 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	2102	Aug 23, 2025 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	1072	Aug 21, 2025 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	1185	Aug 19, 2025 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	185450	Aug 13, 2025 by mmwain
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