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

Members Login
Post Info TOPIC: "Modernising" a 1993 Yamaha TTR250 Open Enduro


Super Guru

Status: Offline
Posts: 7313
Date:
MOT woes!
Permalink  
 


The TTR failed its MOT this morning. There is a crack in the RH bearing housing as shown in the photo below. So my job this afternoon is to strip out the wheel and lace in a replacement hub!

I genuinely hadn't spotted the crack and can't think what caused it confuse

Cracked hub.jpg



__________________

Exeter, Devon, UK

http://www.ttr250.com  - The one and only dedicated TTR250 FAQ! 
 

TIP: For easy viewing bookmark the "Recent Posts" view - http://ttr250.activeboard.com/p/recent/ 



Super Guru

Status: Offline
Posts: 1808
Date:
RE: "Modernising" a 1993 Yamaha TTR250 Open Enduro
Permalink  
 


To many pastieswinkwinkwink



__________________

totallyttrs.com

 



Super Guru

Status: Offline
Posts: 1726
Date:
Permalink  
 

Road pothole.



__________________

Pete. South Somerset, England.



Super Guru

Status: Offline
Posts: 7313
Date:
Permalink  
 

Probably a combination of both disbelief

Anyways up, the fix took a lot longer than expected cry

I didn't have a spare front hub so had to rob one off another wheel that had a cracked rim.

36 spokes needed to be released and I managed to get about a quarter undone without the spoke snapping. Took ages.

Cleaned up hub and fitted new bearings and seals. Not my day as the bearings did NOT want to come out.

Removed tyre and tube from the wheel with the damaged hub and stripped out the spokes. This was a lot easier as it wasn't long ago I fitted a new set of spokes.

Laced up the "new" hub to the old powder-coated rim but got the sequencing wrong so undid the lot and started again. 36 spokes remember no

Balanced and trued the wheel, fitted the brake disc and refitted the tyre and tube making sure that I got the direction of rotation correct.

Fitted wheel to bike after leaving it out for a while to make sure it was holding air.

Job done but, having listed the steps, I can see why it took so long!

Replacement hub fitted.jpg

 

I am hoping I can book it in for a retest tomorrow but we will see.

Brian



__________________

Exeter, Devon, UK

http://www.ttr250.com  - The one and only dedicated TTR250 FAQ! 
 

TIP: For easy viewing bookmark the "Recent Posts" view - http://ttr250.activeboard.com/p/recent/ 



Super Guru

Status: Offline
Posts: 7313
Date:
Permalink  
 

Now that I have sold Totally TTRs the "shopping" TTR can be moved on. I no longer need it for the daily run (when it was dry!) to the Post Office or for testing digital speedos and their associated senders (Steve has his own white TTR to use for this).

There seems to be a better market for trail TTRs so the bike has been converted from this:

13th April 2015.jpg

 

to this:

RHS trail.jpg

LHS trail.jpg

 

The conversion involved removing the mirrors, rack and top box and fitting grab handles, a new Totally TTRs sump guard, 13/48 gearing and trail tyres front and rear. It already has Dakar High bars, handguards, rear disc guard and frame guards.

Just to recap and update on the project:

The TTR was originally a white metal-tanked model and has been updated using the tank, side panels, mudguards and seat from the later blue model.

It has had a complete nut and bolt rebuild starting with a powder coated frame

The engine was completely rebuilt and taken out to 263cc.

In the rebuild the TTR was fitted with:

  1. Motad after-market exhaust (100% stainless steel) and a Totally TTRs shorty header pipe
  2. Aluminium decompressor plug
  3. Sprag clutch, starter gears and starter motor
  4. Main bearings, big end bearing, conrod and rebored to 263cc
  5. Gear-change and transmission shaft oil seals
  6. Cam chain
  7. Swing arm and linkage bearings and seals
  8. Chain slider
  9. Steering head bearings and seals
  10. Fork oil and dust seals
  11. Complete new genuine Yamaha seat 
  12. Polisport fork gaiters
  13. Renthal Dakar bars
  14. Symtec heated grips – heated pads that fit under the grips with two heat settings
  15. Totally TTRs special long clutch and throttle cables made by Venhill
  16. Hel braided front brake hose
  17. Renthal R3 chain and (13/48) sprockets with chrome counter-sunk bolts on the rear sprocket
  18. Wheel rims and hubs powder coated and re-spoked
  19. Wheel bearings and seals
  20. Mudguard brace
  21. ProGrip wrap-around handguards and grips
  22. D&D full graphics kit
  23. Totally TTRs full sump guard (the best on the market!)
  24. Totally TTRs rear disc guard and stainless steel (not lightweight aluminium) frame guards.

The engine and gearbox unit have been soda blasted and painted in two-pack paint with lacquer finish.

The TTR has the original digital speedo and warning light cluster. It has been fitted with a DRD “speedo healer” which makes the speedo read in mph. The speedo sender has also been fitted with the Totally TTRs aluminium cover that allows a better view of the front sprocket and improved access for cleaning.

It will be nice to have a bit of extra room in the garage when it goes biggrinbiggrinbiggrin

Brian



__________________

Exeter, Devon, UK

http://www.ttr250.com  - The one and only dedicated TTR250 FAQ! 
 

TIP: For easy viewing bookmark the "Recent Posts" view - http://ttr250.activeboard.com/p/recent/ 



Super Guru

Status: Offline
Posts: 1808
Date:
Permalink  
 

Very nice indeed, you are the gurusmilesmilesmile



__________________

totallyttrs.com

 



Super Guru

Status: Offline
Posts: 7313
Date:
Permalink  
 

Sold tonight and will be off to its new home in North Devon at the weekend biggrin



__________________

Exeter, Devon, UK

http://www.ttr250.com  - The one and only dedicated TTR250 FAQ! 
 

TIP: For easy viewing bookmark the "Recent Posts" view - http://ttr250.activeboard.com/p/recent/ 



Super Guru

Status: Offline
Posts: 7313
Date:
Permalink  
 

Just saw that this thread has had just under 37.000 hits - amazing shocked.gif



__________________

Exeter, Devon, UK

http://www.ttr250.com  - The one and only dedicated TTR250 FAQ! 
 

TIP: For easy viewing bookmark the "Recent Posts" view - http://ttr250.activeboard.com/p/recent/ 



Super Guru

Status: Offline
Posts: 1808
Date:
Permalink  
 

Is that the most everconfuse



__________________

totallyttrs.com

 



Senior Member

Status: Offline
Posts: 202
Date:
RE: rebuild
Permalink  
 


the views/hits are justified.... excellent work!



__________________

  Europe & Turkey for under £900.00! https://www.youtube.com/watch?v=Z2yTtFPM7Xc



Super Guru

Status: Offline
Posts: 7313
Date:
RE: "Modernising" a 1993 Yamaha TTR250 Open Enduro
Permalink  
 


I apologise to anyone that has trawled through this thread. I hadn't realised how many photos had gone AWOL because Photobucket closed my free account disbelief

It has been a long job but I think I have now recovered all the photos correctly plus repaired or deleted broken links.

If you spot any remaining flaws please PM me with the date of the post and what's wrong wink

Brian



__________________

Exeter, Devon, UK

http://www.ttr250.com  - The one and only dedicated TTR250 FAQ! 
 

TIP: For easy viewing bookmark the "Recent Posts" view - http://ttr250.activeboard.com/p/recent/ 



Senior Member

Status: Offline
Posts: 103
Date:
RE: thank you
Permalink  
 


Respect and much appreciation for your effort in restoring photofukits terrorism. I really enjoyed reading the thread and am sure to use it again one day.



__________________


Member

Status: Offline
Posts: 21
Date:
thanks
Permalink  
 


Well done...a lot of work to keep everybody informed thanks for your time



__________________
«First  <  1 2 3 4 | Page of 4  sorted by
 
Quick Reply

Please log in to post quick replies.



Create your own FREE Forum
Report Abuse
Powered by ActiveBoard