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

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...

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...

Don · Don

I have a blue tank ttr 250. The bike does not charge the battery, i have changed the rectifier, checked the voltage at the battery with the engine running. no increase of voltage as engine revs up. checked the connections. The bike will last a days ride if i charge the battery. I suspect it is the stator...

markjlo · markjlo

Hi guys my M reg 249cc failed its MOT front and rear brake pads. The bike shop cant find the replacement pads when looks online - can anyone help with replacing the pads please

Elephant · Elephant

Hi, In many ways, a TTR looks like the perfect bike for me, light & powerful enough for my needs, however the oil change frequency will be a bit of an issue. My intention, is to use the bike for:Short trips on the roadGreenlaning/TETLonger, overlanding type trips for weeks/months on mixed road t...

Oplayneo · Oplayneo

I seem to have misplaced my keys somewhere between the Pyrenees and the UK! I have hunted the forum and net but cant find any info on how to remove the barrel? Obviously it is in the off position, no steering lock on though. I am not that bothered in having a key as I don't leave the bike so would be fine to put a...

UncleFZ · UncleFZ

https://ttr250.activeboard.com/t50236179/removing-ignition-barrel-and-finding-the-ignition-key-code-n/

Rossyboys · Rossyboys

Hi All I ride my TTR250 in the dusty outback of NSW Australia (Cobar). More recently the smaller instrument panel had started to get red dust inside the indicators making it harder to see that the bike was in Neutral etc. So I thought others may have a similar problem and the fix was quiet easy. I have at...

TTR250stu · TTR250stu

Hi this is my first post. I bought a 1993 TTR250 open enduro about a year ago and have used it off road a few times where it has been great. I'm about to do my road bike test so was checking the bike over for MOT (it still had one when I bought it) I noticed the indicator warning comes on when the ignition is switc...

deefer · deefer

Good evening all I've put a post in the newbie section with more details and a picture of it but I’m a New TTR owner and currently breathing new life into a 1994 raid model. The tyres on the bike are perished so I want to get some new ones. I’ve sorted a front tyre (TKC80) but stuck on a rear tyre choice, it curr...

TTR-Tom · TTR-Tom

Hello, I'm new to the TTR-250 and new to this forum. While perusing the information available to perform some routine maintenance on a TTR-250 I just purchased, I came across several threads regarding bad sprag clutches. That's when it hit me--my bike may be experiencing the loud bang at shutoff tha...

DTRAL · DTRAL

After fighting the carb and a high-idle issue, I finally got the bike up and running... for a short time, anyway. It's back to fighting me on the idle so it's parked for the summer until I can get it apart and thoroughly sorted. Looking at my engine to try to ID where the various oil seepages are coming fro...

Topic		Started By	Replies	Views	Last Post
	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	509	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	697	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	548	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	499	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	841	Feb 13, 2024 by TTRfan
	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	676	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	913	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	618	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	582	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	481	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	2104	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	568	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	1260	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	720	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	737	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	677	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	784	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	603	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	588	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	1088	Nov 5, 2023 by Rossyboys
	Charging problem (Preview) I have a blue tank ttr 250. The bike does not charge the battery, i have changed the rectifier, checked the voltage at the battery with the engine running. no increase of voltage as engine revs up. checked the connections. The bike will last a days ride if i charge the battery. I suspect it is the stator...	Don	2	749	Nov 1, 2023 by dlee22
	BRAKE PADS (Preview) Hi guys my M reg 249cc failed its MOT front and rear brake pads. The bike shop cant find the replacement pads when looks online - can anyone help with replacing the pads please	markjlo	5	673	Oct 20, 2023 by ttr steve
	Extending oil change frequency? (Preview) Hi, In many ways, a TTR looks like the perfect bike for me, light & powerful enough for my needs, however the oil change frequency will be a bit of an issue. My intention, is to use the bike for:Short trips on the roadGreenlaning/TETLonger, overlanding type trips for weeks/months on mixed road t...	Elephant	5	767	Oct 14, 2023 by Elephant
	Removing ignition barrel and finding the ignition key code number (Preview) I seem to have misplaced my keys somewhere between the Pyrenees and the UK! I have hunted the forum and net but cant find any info on how to remove the barrel? Obviously it is in the off position, no steering lock on though. I am not that bothered in having a key as I don't leave the bike so would be fine to put a...	Oplayneo	34	33677	Oct 2, 2023 by UncleFZ
	Blue tank mounting bolts thread size (Preview) https://ttr250.activeboard.com/t50236179/removing-ignition-barrel-and-finding-the-ignition-key-code-n/	UncleFZ	8	589	Sep 29, 2023 by UncleFZ
	Dust In Instruments Panel Blinker (Preview) Hi All I ride my TTR250 in the dusty outback of NSW Australia (Cobar). More recently the smaller instrument panel had started to get red dust inside the indicators making it harder to see that the bike was in Neutral etc. So I thought others may have a similar problem and the fix was quiet easy. I have at...	Rossyboys	7	666	Sep 29, 2023 by TTRfan
	1993 TTR250 open enduro indicator warning permanently flashing Indicator fault flasher fault indicator warning flasher warning (Preview) Hi this is my first post. I bought a 1993 TTR250 open enduro about a year ago and have used it off road a few times where it has been great. I'm about to do my road bike test so was checking the bike over for MOT (it still had one when I bought it) I noticed the indicator warning comes on when the ignition is switc...	TTR250stu	1	540	Sep 27, 2023 by TTRfan
	What tyres and rear tyre sizes are you using (Preview) Good evening all I've put a post in the newbie section with more details and a picture of it but I’m a New TTR owner and currently breathing new life into a 1994 raid model. The tyres on the bike are perished so I want to get some new ones. I’ve sorted a front tyre (TKC80) but stuck on a rear tyre choice, it curr...	deefer	8	742	Sep 24, 2023 by dlee22
	Sprag Clutch--what does a bad one sound like? (Preview) Hello, I'm new to the TTR-250 and new to this forum. While perusing the information available to perform some routine maintenance on a TTR-250 I just purchased, I came across several threads regarding bad sprag clutches. That's when it hit me--my bike may be experiencing the loud bang at shutoff tha...	TTR-Tom	11	761	Sep 20, 2023 by KTMjase
	Cylinder Question (Preview) After fighting the carb and a high-idle issue, I finally got the bike up and running... for a short time, anyway. It's back to fighting me on the idle so it's parked for the summer until I can get it apart and thoroughly sorted. Looking at my engine to try to ID where the various oil seepages are coming fro...	DTRAL	3	619	Sep 20, 2023 by tripodtiger
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