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

robject33 · robject33

I just did a compression test on my bike for the first time. Here's a video of the first test: https://youtu.be/hdntwR44xtA And here's another video of a second test after putting some engine oil in the cylinder: https://youtu.be/yg6BeBRXtZA The compression builds a lot faster after adding the...

robject33 · robject33

Hey all, I can't seem to dial in the free play and reach of my front brake lever. Even with the reach adjustment dialled in as close to the bars as possible the lever still sits far out. And there's so much free play that the lever hits my knuckles when using the brakes. Here's a video showing the issue: htt...

yamalama · yamalama

Hi all, Just wondering if anyone else has experienced this. When I have not started by TTR for a few month. when I come to start it it turns over easily but doesn’t show any hint of wanting to start. I then try it on the kick start and there is very little resistance. after 20 or 30 kicks resistance builds up...

Jumpn · Jumpn

I changed out front sprocket and chain today. I know it's standard procedure to change rear sprocket also, but it showed little wear at all. My chain adjusters were at 12 before new chain, now they are at 6. I also replaced carburetor float bowl gasket. I went to start it up for the first time since No...

7kilps9 · 7kilps9

Good morning bois. My son bought and rebuilt a 2004 TTR250. It ran rough and wouldn't shift. He split the case. Put in a transmission. Honed the cylinder, new piston, new rings, new valves lapped in and leak tested. He couldn't get it to start. It's got spark. He claims he cleaned the carb out. Timing sho...

Patrik · Patrik

Hi guys i have a 2001 Yamaha ttr250 and when we got it we noticed that when you rev it the revs don't go back to idle they stay at the revs you were on and the only way you can get it back down is if you quickly rev the throttle. We have cleaned the carb checked the throttle cables and checked the choke but nothing...

Dylan Macdonald · Dylan Macdonald

Hi all I was wondering if you can help me I bought a ttr250 about a year ago I noticed the clutch was slipping so I decided to check the clutch plates and saw one plate had been snapped in a few places so I cleaned the motor out got the pieces out and put second hand plates for the mean time it lasted about 2 mon...

TTRider · TTRider

Hi all, I was out a couple of weekends ago on the TTR for the Borders Rally - first rally and a fantastic weekend... until the bike lost all drive! To start with the bike was having trouble finding gear - I'd kick the gear change lever up but it wouldn't find it. From what I remember this was third to four...

TTRfan · TTRfan

Brick cleaning acid works wonders on dirty exhaust headers but an alternative that I have recently found is to use a wire wheel on a bench grinder. Works really well and then just needs finishing off with some relatively fine wet & dry paper and Solvol Autosol. Brian PS Please excuse the messy benc...

TTRfan · TTRfan

I had a couple of clutch covers that I had put to the back of the shelves as I couldn't figure how to repair it and the covers are too valuable to throw away. The challenge is to drill the thread out for the Helicoil insert absolutely at 90 degrees. This is the kit I used - not actually Helicoil but a copy: I enl...

dlee · dlee

So, my daughter's bike is starting to smoke a lot, figure it's time for new rings and piston, looking on Ebay, looks like they offer a few replacements, 73.75 bore, 73mm bore, 73.5 bore, Any idea what size I need, I don't want to pay the inflated Yamaha OEM brand if I don't have too. Thanks -- Edited by dle...

mossproof · mossproof

I have a shift drum bearing that is badly contaminated with aluminium swarf. Anyone know how to change it? How does the star wheel come off the end to pull the bearing off? I can't see it mentioned in my manual at all!

Richard Davies · Richard Davies

Hi there. I've just had an ace day out on the great western trail and the washed out gulley at Midford has claimed my rear shock! Had to ride back sitting on the tank! Where can I send it off to get fixed? Thanks for any help!

Padowan · Padowan

I need to replace the filters on the ends of the petc0ck, on the brass lines that are inside the fuel tank. Does anyone happen to know what the size is of those brass lines, or has an OEM petc0ck kicking around and can measure them - replacement filters seem to come in a few size variants? I will have to tak...

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

oshanrube · oshanrube

Hi all I'm not sure if this is been answered already. I have a charging problem and I checked the stator resistance and it was around 2ohms so I searched for a stator without any luck I ordered a Taiwan coil which was in spec for resistance but had a problem with the pickup which made the bike run super lean c...

alexkram · alexkram

Hi Guys, My 2005 TTR250 has a high pitched noise that gets louder with RPMs and when the engine gets hot. Clutch in or out makes no difference and neither does bike speed. I've only noticed it the last few hundred miles and it's been getting louder. Sometimes the engine makes a hard clunk when it shuts off...

mariaKaigiwnis · mariaKaigiwnis

Hello everyone! Yesterday i noticed that one of the studs that hold the exhaust in place had completely fell off my bike. I had replaced this stud a month ago as the previous one could not get tight enough and i hoped that this may resolve the issue, which unfortunately wasn't the case. The threading tha...

Christos · Christos

Hi all, My bike developed a weird rattling coming from the clutch basket, I think. It stops or minimises when I pull the clutch lever. It is not that annoying but I would like to ask if someone has experienced this and what could the cause be?

robject33 · robject33

Can anyone recommend a good fastners set that is availabe in the UK? I'm talking a big box of nuts, bolts, washers etc that I can have to hand when I need to replace one of the rusty ones that are beyond saving on my bike. Seems like there's always at least one like this that needs replacing when I've done any...

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...

Moabmatt · Moabmatt

I'm kicking myself a bit for this one, but let's see if I can get it running at least. Low compression (45-50 dry), no spark (before me), new wiring harness and tdi box installed by questionable methacanics... Leakdown and simple tests indicate carb, valves, rings, or something bigger. After top e...

Archershome · Archershome

Hello all, I would like some advice on the following. My Kick Start and Electric Start have jammed on my bike, I can move the crank using socket but only some of the way round in either direction before it jams. I have taken CAM cover off and looked at timing chain and valves, you can see that this all looks...

Speedy31470 · Speedy31470

Hi everyone. Thanks to a Forum Guru, I was able to obtain a used oil cooler. I have read the publications which talk about it, in particular the internal screw in the right cover. Do you have any advice for assembly and especially restarting in order to check that the lubrication is good through the cool...

rdchair · rdchair

Exhaust cracked right through today 😟. Don’t think it can be repaired ? So looking at new one . What do the new stainless ones sound like ? Good or too loud ? Keep it standard ? Thoughts ? Cheers

Christos · Christos

I noticed that the shorty header pipe is touching the oil pipe bolt on the right case cover. Could it cause any problem? I don't want to undo the header bolts unless absolutely necessary because one is helicoiled and if it fails the repair will be troublesome. Helicoil cannot be used again...

mariaKaigiwnis · mariaKaigiwnis

Hello everyone. I recently bought a used TTR-250 raid. After a while i noticed that if the bike was left being off for more than 20 hours i would have hard time firing it up again and also i noticed white smoke coming out of the exhaust at high revs (burning oil was my guess). So i decided to do a top end rebuil...

Joss · Joss

Hi If i use my blue tanked ttr250 every day it starts fine on the button , but if i leave it for a week the battery won't turn the engine over , but the lights and horn work fine . Is this normal ? or do i ave a problem , and how do i fix it ?

dlee22 · dlee22

Hi all, We are currently in Colombia just north east of Bogota and are riding some of the biketracking trails. Most the back roads are decent hardpacked tracks with the occasional areas where rai. Has dragged mud and stone. Recently we've been in Venezuela up to 4400m odd, whatever there highest roa...

Hawk427 · Hawk427

I recently purchased a '99 TTR250 with a no start problem. Turns out its not getting a spark. Today I took to diagnosing the problem. I have been searching the forums for the past couple of days trying to find a solution, but no luck. Things that tested fine: Main fuse Battery Starter Starter Relay Main...

Topic		Started By	Replies	Views	Last Post
	Compression test results - not sure if they are okay? (Preview) I just did a compression test on my bike for the first time. Here's a video of the first test: https://youtu.be/hdntwR44xtA And here's another video of a second test after putting some engine oil in the cylinder: https://youtu.be/yg6BeBRXtZA The compression builds a lot faster after adding the...	robject33	3	510	Apr 20, 2024 by JOHNYBOY
	Excessive brake lever play (Preview) Hey all, I can't seem to dial in the free play and reach of my front brake lever. Even with the reach adjustment dialled in as close to the bars as possible the lever still sits far out. And there's so much free play that the lever hits my knuckles when using the brakes. Here's a video showing the issue: htt...	robject33	4	553	Apr 20, 2024 by robject33
	Low compression after standing for months (Preview) Hi all, Just wondering if anyone else has experienced this. When I have not started by TTR for a few month. when I come to start it it turns over easily but doesn’t show any hint of wanting to start. I then try it on the kick start and there is very little resistance. after 20 or 30 kicks resistance builds up...	yamalama	8	622	Apr 19, 2024 by ttr steve
	front sprocket changed, float bowl gasket changed, won't start (Preview) I changed out front sprocket and chain today. I know it's standard procedure to change rear sprocket also, but it showed little wear at all. My chain adjusters were at 12 before new chain, now they are at 6. I also replaced carburetor float bowl gasket. I went to start it up for the first time since No...	Jumpn	22	8055	Mar 21, 2024 by TTRfan
	2004 Ttr250 cranks, sparks, has gas, won't fire (Preview) Good morning bois. My son bought and rebuilt a 2004 TTR250. It ran rough and wouldn't shift. He split the case. Put in a transmission. Honed the cylinder, new piston, new rings, new valves lapped in and leak tested. He couldn't get it to start. It's got spark. He claims he cleaned the carb out. Timing sho...	7kilps9	7	581	Mar 21, 2024 by TTRfan
	Help - my TTR stays on high revs!!!!!! choke throttle carb throttleproblems help (Preview) Hi guys i have a 2001 Yamaha ttr250 and when we got it we noticed that when you rev it the revs don't go back to idle they stay at the revs you were on and the only way you can get it back down is if you quickly rev the throttle. We have cleaned the carb checked the throttle cables and checked the choke but nothing...	Patrik	47	75873	Mar 15, 2024 by ttr steve
	Ttr250 (Preview) Hi all I was wondering if you can help me I bought a ttr250 about a year ago I noticed the clutch was slipping so I decided to check the clutch plates and saw one plate had been snapped in a few places so I cleaned the motor out got the pieces out and put second hand plates for the mean time it lasted about 2 mon...	Dylan Macdonald	2	475	Mar 13, 2024 by Dylan Macdonald
	Gearchange return spring retaining post problems (Preview) Hi all, I was out a couple of weekends ago on the TTR for the Borders Rally - first rally and a fantastic weekend... until the bike lost all drive! To start with the bike was having trouble finding gear - I'd kick the gear change lever up but it wouldn't find it. From what I remember this was third to four...	TTRider	13	2218	Mar 11, 2024 by mossproof
	Cleaning exhaust header pipes (Preview) Brick cleaning acid works wonders on dirty exhaust headers but an alternative that I have recently found is to use a wire wheel on a bench grinder. Works really well and then just needs finishing off with some relatively fine wet & dry paper and Solvol Autosol. Brian PS Please excuse the messy benc...	TTRfan	1	487	Mar 10, 2024 by Mortown
	Fitting a Helicoil to repair a stripped banjo bolt thread (Preview) I had a couple of clutch covers that I had put to the back of the shelves as I couldn't figure how to repair it and the covers are too valuable to throw away. The challenge is to drill the thread out for the Helicoil insert absolutely at 90 degrees. This is the kit I used - not actually Helicoil but a copy: I enl...	TTRfan	0	379	Mar 10, 2024 by TTRfan
	Bore size on a 2000 TTR250 (Preview) So, my daughter's bike is starting to smoke a lot, figure it's time for new rings and piston, looking on Ebay, looks like they offer a few replacements, 73.75 bore, 73mm bore, 73.5 bore, Any idea what size I need, I don't want to pay the inflated Yamaha OEM brand if I don't have too. Thanks -- Edited by dle...	dlee	1	596	Feb 23, 2024 by mossproof
	Transmission shift drum bearing (Preview) I have a shift drum bearing that is badly contaminated with aluminium swarf. Anyone know how to change it? How does the star wheel come off the end to pull the bearing off? I can't see it mentioned in my manual at all!	mossproof	2	461	Feb 17, 2024 by mossproof
	Rear shock gone soggy! (Preview) Hi there. I've just had an ace day out on the great western trail and the washed out gulley at Midford has claimed my rear shock! Had to ride back sitting on the tank! Where can I send it off to get fixed? Thanks for any help!	Richard Davies	0	430	Feb 16, 2024 by Richard Davies
	Fuel petc0ck filter size (Preview) I need to replace the filters on the ends of the petc0ck, on the brass lines that are inside the fuel tank. Does anyone happen to know what the size is of those brass lines, or has an OEM petc0ck kicking around and can measure them - replacement filters seem to come in a few size variants? I will have to tak...	Padowan	9	692	Feb 13, 2024 by TTRfan
	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	174	171386	Feb 10, 2024 by mossproof
	Stator coil output (Preview) Hi all I'm not sure if this is been answered already. I have a charging problem and I checked the stator resistance and it was around 2ohms so I searched for a stator without any luck I ordered a Taiwan coil which was in spec for resistance but had a problem with the pickup which made the bike run super lean c...	oshanrube	3	568	Feb 2, 2024 by dlee22
	High pitched engine noise, louder when hot (Preview) Hi Guys, My 2005 TTR250 has a high pitched noise that gets louder with RPMs and when the engine gets hot. Clutch in or out makes no difference and neither does bike speed. I've only noticed it the last few hundred miles and it's been getting louder. Sometimes the engine makes a hard clunk when it shuts off...	alexkram	12	759	Jan 24, 2024 by Ttboof
	Exhaust stud threading issue (Preview) Hello everyone! Yesterday i noticed that one of the studs that hold the exhaust in place had completely fell off my bike. I had replaced this stud a month ago as the previous one could not get tight enough and i hoped that this may resolve the issue, which unfortunately wasn't the case. The threading tha...	mariaKaigiwnis	5	531	Jan 22, 2024 by Nev
	Rattling from clutch basket (Preview) Hi all, My bike developed a weird rattling coming from the clutch basket, I think. It stops or minimises when I pull the clutch lever. It is not that annoying but I would like to ask if someone has experienced this and what could the cause be?	Christos	3	502	Jan 20, 2024 by JOHNYBOY
	Fasteners set (Preview) Can anyone recommend a good fastners set that is availabe in the UK? I'm talking a big box of nuts, bolts, washers etc that I can have to hand when I need to replace one of the rusty ones that are beyond saving on my bike. Seems like there's always at least one like this that needs replacing when I've done any...	robject33	0	412	Jan 20, 2024 by robject33
	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	33	1829	Jan 10, 2024 by Ttboof
	2005 ttr low compression, no start, rings, valves (Preview) I'm kicking myself a bit for this one, but let's see if I can get it running at least. Low compression (45-50 dry), no spark (before me), new wiring harness and tdi box installed by questionable methacanics... Leakdown and simple tests indicate carb, valves, rings, or something bigger. After top e...	Moabmatt	1	477	Jan 2, 2024 by mossproof
	Kick Start and Electric Start Jammed (Preview) Hello all, I would like some advice on the following. My Kick Start and Electric Start have jammed on my bike, I can move the crank using socket but only some of the way round in either direction before it jams. I have taken CAM cover off and looked at timing chain and valves, you can see that this all looks...	Archershome	5	1163	Jan 2, 2024 by ttr steve
	Install an oil cooler (Preview) Hi everyone. Thanks to a Forum Guru, I was able to obtain a used oil cooler. I have read the publications which talk about it, in particular the internal screw in the right cover. Do you have any advice for assembly and especially restarting in order to check that the lubrication is good through the cool...	Speedy31470	2	608	Dec 22, 2023 by Cubber
	Exhaust -Stainless/standard / repair (Preview) Exhaust cracked right through today 😟. Don’t think it can be repaired ? So looking at new one . What do the new stainless ones sound like ? Good or too loud ? Keep it standard ? Thoughts ? Cheers	rdchair	5	630	Dec 18, 2023 by ttr steve
	Exhaust header touching oil pipe bolt (Preview) I noticed that the shorty header pipe is touching the oil pipe bolt on the right case cover. Could it cause any problem? I don't want to undo the header bolts unless absolutely necessary because one is helicoiled and if it fails the repair will be troublesome. Helicoil cannot be used again...	Christos	7	612	Dec 7, 2023 by ttr steve
	TTR-250 loud tick sound after rebuild (Preview) Hello everyone. I recently bought a used TTR-250 raid. After a while i noticed that if the bike was left being off for more than 20 hours i would have hard time firing it up again and also i noticed white smoke coming out of the exhaust at high revs (burning oil was my guess). So i decided to do a top end rebuil...	mariaKaigiwnis	11	703	Nov 28, 2023 by mariaKaigiwnis
	battery and starting ? (Preview) Hi If i use my blue tanked ttr250 every day it starts fine on the button , but if i leave it for a week the battery won't turn the engine over , but the lights and horn work fine . Is this normal ? or do i ave a problem , and how do i fix it ?	Joss	1	534	Nov 24, 2023 by TTRfan
	3000m severe bogging. (Preview) Hi all, We are currently in Colombia just north east of Bogota and are riding some of the biketracking trails. Most the back roads are decent hardpacked tracks with the occasional areas where rai. Has dragged mud and stone. Recently we've been in Venezuela up to 4400m odd, whatever there highest roa...	dlee22	8	492	Nov 23, 2023 by Ttboof
	Another "No Spark" thread. Help! (Preview) I recently purchased a '99 TTR250 with a no start problem. Turns out its not getting a spark. Today I took to diagnosing the problem. I have been searching the forums for the past couple of days trying to find a solution, but no luck. Things that tested fine: Main fuse Battery Starter Starter Relay Main...	Hawk427	3	857	Nov 5, 2023 by Rossyboys
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