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

micccki · micccki

Hi All, i have just replaced the piston rings, done valve clearances to 0.010 " exhaust and 0.007" on inlet. Also replaced sprag clutch. On trying bike out, there is a huge rattle from the engine on over run. About 5 or 6 sprags were out of ther race on arrival, which i have replaced. On talking with st...

Martinm · Martinm

Hi all I am just checking my carb before putting it I'm my bike and I understand by reading other post that when you open the throttle it should spray petrol out, but mine is not doing this have any of you guys come across this before if so is it an easy fix? I have checked the diafram that's still in one piece...

Shanemhi · Shanemhi

hi guys, Just getting my 93 OE ready for MOT and my polisport headlight flickers and goes out under revs but is fine at idle, can't find any dubious wires so just thought I'd ask just in case someone had encountered this problem?? Cheers in advance Shane

Lurkville · Lurkville

Hey crew, new to the forum. I own a 2001 TTR for my girlfriend to kick around. Just starting to tear down the motor, and found that the smaller plug (flathead) on the crankcase cover is completely seized. Tried a flathead amongst other things and can’t get it to budge. i can’t belive they used a flathead d...

Brighton Brad · Brighton Brad

Hi guys, which direction should the starter motor spin. I have removed the generator cover and can se the splines of the starter motor. I'm doing the Sprag clutch and have replaced the starter motor brushes also, there was lots of whirring with everything togethe, but a lack of starting, cheers all, B...

TTRfan · TTRfan

An excellent article I just read on Adventure Rider - see here There is an excellent explanation of the different types of Loctite available. I had no clue that the green "wicking" solution existed let alone how cleverly it works! Brian

Stephen68 · Stephen68

Guys, i have an 03 TTR 250 that is missing the the exhaust header flange bolts.....I looked on the schematics but cant find a part number for them. Can someone tell me what they are please?

Stephen68 · Stephen68

Guys, i just replaced my timing chain, piston, valve seals and rings. After putting everything back together and attempting to start it all it would do is crank with an occasional small pop back through the air filter. After ensuring that my flywheel was TDC on the single up and down line i removed the c...

een705 · een705

I am waiting for a multi meter to arrive soon but this is my problem there is no display at the moment. I can take the headlight cowl off and pull the connection that connects to the speedo and plug it back in and it works but when I put the headlight cover back on and turn the ignition off and back on and it will...

650Katman · 650Katman

I have a strange problem. My OE digital speedo appears to have reset the km's. Not the trip km's but the main reading. Or am I being a bit thick and not pressing correct buttons or need to press one. I have read through and tried red and blue combinations to no avail. My speedo now says 50km's

TTRfan · TTRfan

TTR Steve has always been a bit less than enthusiastic about taking on mechanical jobs. His excuse being that something always seemed to go pear shaped on his projects. I thought perhaps it was a bit of an excuse not to get oil under his finger nails However, having worked with him for a few days buildin...

AngusLT28 · AngusLT28

Does anyone know the specs of the 2 bolts used to bolt the exhaust on to the frame(after the cannon slides onto the header pipe). I have lost the back one on my recent ride and one closest to the header is nearly stripped. I tried an M8, and the thread was similar though wasnt correct. NOTE- These two bol...

TTRFunrider · TTRFunrider

Hi, new here, can anyone help? I've got a problem with my 2001 ttr250! I hadn't used it for nearly a year, but started & ran it regularly though..... I realised over the last few times that it ran perfectly on the choke but when I switched off the choke it had started searching for an idle, popping &...

Stephen68 · Stephen68

Hello everyone, and as the title says, i forgot to set my motor to TDC before i removed the top end for a re ring and cleaning. My question, what do i need to do in order to make sure i have no problems after reassembly? I know how to set the timing etc. but i am concerned that i forgot to do this before i disassem...

een705 · een705

I have read loads about sprag and didnt want to hijack the one below. My bike makes a clunk its not very loud but its there so I did some reading on here and looked behing the cover near the starter. The idler gear is damaged but the starter should be okay. I have added a picture of gears but what do you people r...

denisgavriloff · denisgavriloff

I have a 2002 TTR250. It has been maintained well throughout the last couple of months since I bought it. Last Saturday morning, I tried to start it up with the choke and it started right up. Couple minutes later, however, it died and wouldn't start up again. I decided that it might be the carb that need...

leigh · leigh

Hey peeps Anyone had the experience of the aluminium with o-ring blanking plug leaking? I think I put it in about a year ago. I guess I'll pull it out and clean it and maybe use some sealant as well this time? Cheers Leigh.

TTRfan · TTRfan

Every day is a school day! Although it was possible to adjust the clutch on Steve's 350 build to get the pointer in the correct position (see here), the bolt did seem a long way in. Shoulda realised that the bolt was from a 6-plate clutch and Steve was upgrading to a 7-plate which, ideally, requires a long...

tom13 · tom13

Google translator Excuse me, what is it? the photo has turned over -- Edited by tom13 on Sunday 14th of October 2018 06:19:16 PM

Gavinm · Gavinm

Hi All, New to the forum.. hope you're all well. I recently picked up a 2006 TTR250. It was not running but I've managed to get her going. There's a strange problem that I can't work out. When I start it cold, with the choke on she runs quickly to high revs then settles down to lower RPM after a few seconds. ...

mallywoods · mallywoods

Hello all, my 1999 250 TTR Enduro is brilliant and love it only used to go to the shops on dry days.only 8800kms. Reading posts on this page it appears that to hear a clunk when the engine is turned of is a sign that a sprag clutch is on its way out. My bike starts and runs fine. Do I have a problem???? My only s...

ttboof · ttboof

When putting my bike back together I found my clamp on the air filter side of the carby wasn't clamping tight enough. To keep the original clamp I cut a cable tie (flat end ) so it was a neat fit around the tube then put the clamp back on over the cut down tie end Result was a good tight clamp again -- Edited...

Ross · Ross

Hi All My bike has developed a pronounced squeak when the rear suspension is compressed and rebounds and i am wondering what to do I'm am trying to do all my own maintenance but am learning slowly i have looked at the links on suspension but not sure where to start!? Any help would be gratefully received I...

robs · robs

Hey, Anyone know how to disconnect the front brake light connector from the master cylinder mount? I've pulled back the rubber to reveal some kind of plastic that looks like it encapsulates the spade connectors.. was getting dark so didn't get a chance to faff about trying to get it off but there didn'...

TTRfan · TTRfan

I found a great tip from Lin on an old thread of his which is to get yourself a Pentel White 100WM marker pen. About £4 inc p&p from eBay. An example here. Marking some parts before disassembly can be very helpful come the rebuild. The ink will survive extremely well and is resistant to oil and grease...

een705 · een705

Not been on the forum long and hope someone can help...my clutch is slipping and having read the threads checked the adjustment, changed the oil and measured the plates which are reading 2.9mm-3mm put it all back together and its still slipping. Im sure the adjustment of the arm is in the right place bu...

tom13 · tom13

Google Translate- Good morning. I want to unscrew the oil filter cover and here is the poverty. 1 Allen screw is round inside. The second one is for a screwdriver and the thread in the motor is broken. A bit of a problem. What advice is there? What dimensions do the original screws have? I advised mysel...

650Katman · 650Katman

Hi all, I got my ttr oe last Friday. All was well. I discovered original air filter was not all there. About a 1/4 of it had fell apart and was mostly crumbled in the air box. New air filter fitted after cleaning crud out of airbox. On my way home from work Friday night bike slowed and spluttered, time to go to...

leigh · leigh

Just thought I'd post this here, I replaced my bars a while ago with Protaper - Seven Eighths - YZ high bend - they are exactly the same as standard but much stronger Alloy ones. In case its handy for someone else I thought I'd post it up. Cheers Leigh.

Rydasc6102 · Rydasc6102

I was doing a check over my bike and it looks like the previous owner put the chain roller in the wrong spot when installing the skid plates. Am I correct? Do I just unbolt it and put it below or are there washers That could be missing?

Topic		Started By	Replies	Views	Last Post
	engine noise. (Preview) Hi All, i have just replaced the piston rings, done valve clearances to 0.010 " exhaust and 0.007" on inlet. Also replaced sprag clutch. On trying bike out, there is a huge rattle from the engine on over run. About 5 or 6 sprags were out of ther race on arrival, which i have replaced. On talking with st...	micccki	5	1489	Nov 24, 2018 by micccki
	Carb repair (Preview) Hi all I am just checking my carb before putting it I'm my bike and I understand by reading other post that when you open the throttle it should spray petrol out, but mine is not doing this have any of you guys come across this before if so is it an easy fix? I have checked the diafram that's still in one piece...	Martinm	9	2031	Nov 24, 2018 by Martinm
	Headlight goes out under revs but not at idle! (Preview) hi guys, Just getting my 93 OE ready for MOT and my polisport headlight flickers and goes out under revs but is fine at idle, can't find any dubious wires so just thought I'd ask just in case someone had encountered this problem?? Cheers in advance Shane	Shanemhi	4	1093	Nov 20, 2018 by ttboof
	Crankcase plug is seized (flathead) (Preview) Hey crew, new to the forum. I own a 2001 TTR for my girlfriend to kick around. Just starting to tear down the motor, and found that the smaller plug (flathead) on the crankcase cover is completely seized. Tried a flathead amongst other things and can’t get it to budge. i can’t belive they used a flathead d...	Lurkville	13	1165	Nov 11, 2018 by TTRfan
	Starter motor direction?? (Preview) Hi guys, which direction should the starter motor spin. I have removed the generator cover and can se the splines of the starter motor. I'm doing the Sprag clutch and have replaced the starter motor brushes also, there was lots of whirring with everything togethe, but a lack of starting, cheers all, B...	Brighton Brad	4	1420	Nov 8, 2018 by TTRfan
	Preventive Bike Maintenance: The Fastener Algorithm (Preview) An excellent article I just read on Adventure Rider - see here There is an excellent explanation of the different types of Loctite available. I had no clue that the green "wicking" solution existed let alone how cleverly it works! Brian	TTRfan	0	1196	Nov 8, 2018 by TTRfan
	Technical Question lol - exhaust header flange bolts (Preview) Guys, i have an 03 TTR 250 that is missing the the exhaust header flange bolts.....I looked on the schematics but cant find a part number for them. Can someone tell me what they are please?	Stephen68	2	5682	Nov 7, 2018 by heffh084
	Does something look wrong? ....Pictures Included! (Preview) Guys, i just replaced my timing chain, piston, valve seals and rings. After putting everything back together and attempting to start it all it would do is crank with an occasional small pop back through the air filter. After ensuring that my flywheel was TDC on the single up and down line i removed the c...	Stephen68	3	1143	Nov 4, 2018 by ttboof
	Digital Speedo TTR OE (Preview) I am waiting for a multi meter to arrive soon but this is my problem there is no display at the moment. I can take the headlight cowl off and pull the connection that connects to the speedo and plug it back in and it works but when I put the headlight cover back on and turn the ignition off and back on and it will...	een705	10	1951	Nov 3, 2018 by een705
	Speedo Reset (Preview) I have a strange problem. My OE digital speedo appears to have reset the km's. Not the trip km's but the main reading. Or am I being a bit thick and not pressing correct buttons or need to press one. I have read through and tried red and blue combinations to no avail. My speedo now says 50km's	650Katman	1	926	Oct 27, 2018 by TTRfan
	Some people have all the (bad) luck! (Preview) TTR Steve has always been a bit less than enthusiastic about taking on mechanical jobs. His excuse being that something always seemed to go pear shaped on his projects. I thought perhaps it was a bit of an excuse not to get oil under his finger nails However, having worked with him for a few days buildin...	TTRfan	6	1055	Oct 25, 2018 by TTRfan
	Exhaust Bolts Exhaust (Preview) Does anyone know the specs of the 2 bolts used to bolt the exhaust on to the frame(after the cannon slides onto the header pipe). I have lost the back one on my recent ride and one closest to the header is nearly stripped. I tried an M8, and the thread was similar though wasnt correct. NOTE- These two bol...	AngusLT28	2	1802	Oct 23, 2018 by mossproof
	Backfire @ idle, through carb (Preview) Hi, new here, can anyone help? I've got a problem with my 2001 ttr250! I hadn't used it for nearly a year, but started & ran it regularly though..... I realised over the last few times that it ran perfectly on the choke but when I switched off the choke it had started searching for an idle, popping &...	TTRFunrider	4	1539	Oct 22, 2018 by TTRFunrider
	Help! I forgot to set cam TDC before removing them! (Preview) Hello everyone, and as the title says, i forgot to set my motor to TDC before i removed the top end for a re ring and cleaning. My question, what do i need to do in order to make sure i have no problems after reassembly? I know how to set the timing etc. but i am concerned that i forgot to do this before i disassem...	Stephen68	6	4523	Oct 21, 2018 by TTRfan
	Another sprag and idler gears (Preview) I have read loads about sprag and didnt want to hijack the one below. My bike makes a clunk its not very loud but its there so I did some reading on here and looked behing the cover near the starter. The idler gear is damaged but the starter should be okay. I have added a picture of gears but what do you people r...	een705	11	1530	Oct 20, 2018 by een705
	Randomly stopped starting carburetor no start up (Preview) I have a 2002 TTR250. It has been maintained well throughout the last couple of months since I bought it. Last Saturday morning, I tried to start it up with the choke and it started right up. Couple minutes later, however, it died and wouldn't start up again. I decided that it might be the carb that need...	denisgavriloff	9	1969	Oct 19, 2018 by ttboof
	Decompressor blanking plug now weeping (Preview) Hey peeps Anyone had the experience of the aluminium with o-ring blanking plug leaking? I think I put it in about a year ago. I guess I'll pull it out and clean it and maybe use some sealant as well this time? Cheers Leigh.	leigh	9	1782	Oct 18, 2018 by ttr steve
	Clutch adjuster - bolt lengths (Preview) Every day is a school day! Although it was possible to adjust the clutch on Steve's 350 build to get the pointer in the correct position (see here), the bolt did seem a long way in. Shoulda realised that the bolt was from a 6-plate clutch and Steve was upgrading to a 7-plate which, ideally, requires a long...	TTRfan	1	1178	Oct 15, 2018 by mossproof
	what is it (Preview) Google translator Excuse me, what is it? the photo has turned over -- Edited by tom13 on Sunday 14th of October 2018 06:19:16 PM	tom13	2	944	Oct 14, 2018 by tom13
	Strange running! (Preview) Hi All, New to the forum.. hope you're all well. I recently picked up a 2006 TTR250. It was not running but I've managed to get her going. There's a strange problem that I can't work out. When I start it cold, with the choke on she runs quickly to high revs then settles down to lower RPM after a few seconds. ...	Gavinm	9	1290	Oct 14, 2018 by ttboof
	Clunk noise when engine is switched off. (Preview) Hello all, my 1999 250 TTR Enduro is brilliant and love it only used to go to the shops on dry days.only 8800kms. Reading posts on this page it appears that to hear a clunk when the engine is turned of is a sign that a sprag clutch is on its way out. My bike starts and runs fine. Do I have a problem???? My only s...	mallywoods	3	1717	Oct 12, 2018 by een705
	Carby clamp bodge (Preview) When putting my bike back together I found my clamp on the air filter side of the carby wasn't clamping tight enough. To keep the original clamp I cut a cable tie (flat end ) so it was a neat fit around the tube then put the clamp back on over the cut down tie end Result was a good tight clamp again -- Edited...	ttboof	1	1116	Oct 12, 2018 by TTRfan
	Squeaky Suspension (Preview) Hi All My bike has developed a pronounced squeak when the rear suspension is compressed and rebounds and i am wondering what to do I'm am trying to do all my own maintenance but am learning slowly i have looked at the links on suspension but not sure where to start!? Any help would be gratefully received I...	Ross	7	1127	Oct 10, 2018 by ttr steve
	Disconnecting brake light switch on front brake lever housing.. (Preview) Hey, Anyone know how to disconnect the front brake light connector from the master cylinder mount? I've pulled back the rubber to reveal some kind of plastic that looks like it encapsulates the spade connectors.. was getting dark so didn't get a chance to faff about trying to get it off but there didn'...	robs	8	1462	Oct 10, 2018 by robs
	White marker pens to assist in re-assembly of parts (Preview) I found a great tip from Lin on an old thread of his which is to get yourself a Pentel White 100WM marker pen. About £4 inc p&p from eBay. An example here. Marking some parts before disassembly can be very helpful come the rebuild. The ink will survive extremely well and is resistant to oil and grease...	TTRfan	1	1246	Oct 10, 2018 by robs
	clutch slip (Preview) Not been on the forum long and hope someone can help...my clutch is slipping and having read the threads checked the adjustment, changed the oil and measured the plates which are reading 2.9mm-3mm put it all back together and its still slipping. Im sure the adjustment of the arm is in the right place bu...	een705	5	1369	Oct 9, 2018 by een705
	I want to unscrew the oil filter cover (Preview) Google Translate- Good morning. I want to unscrew the oil filter cover and here is the poverty. 1 Allen screw is round inside. The second one is for a screwdriver and the thread in the motor is broken. A bit of a problem. What advice is there? What dimensions do the original screws have? I advised mysel...	tom13	9	1300	Oct 5, 2018 by tom13
	not starting (Preview) Hi all, I got my ttr oe last Friday. All was well. I discovered original air filter was not all there. About a 1/4 of it had fell apart and was mostly crumbled in the air box. New air filter fitted after cleaning crud out of airbox. On my way home from work Friday night bike slowed and spluttered, time to go to...	650Katman	6	1164	Oct 1, 2018 by TTRfan
	Standard bars are the same shape as... (Preview) Just thought I'd post this here, I replaced my bars a while ago with Protaper - Seven Eighths - YZ high bend - they are exactly the same as standard but much stronger Alloy ones. In case its handy for someone else I thought I'd post it up. Cheers Leigh.	leigh	5	2235	Sep 30, 2018 by PlumasDude
	Chain roller (Preview) I was doing a check over my bike and it looks like the previous owner put the chain roller in the wrong spot when installing the skid plates. Am I correct? Do I just unbolt it and put it below or are there washers That could be missing?	Rydasc6102	4	1867	Sep 29, 2018 by petenz
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