Anyways up, the fix took a lot longer than expected
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
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!
I am hoping I can book it in for a retest tomorrow but we will see.
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:
to this:
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:
Motad after-market exhaust (100% stainless steel) and a Totally TTRs shorty header pipe
Aluminium decompressor plug
Sprag clutch, starter gears and starter motor
Main bearings, big end bearing, conrod and rebored to 263cc
Gear-change and transmission shaft oil seals
Cam chain
Swing arm and linkage bearings and seals
Chain slider
Steering head bearings and seals
Fork oil and dust seals
Complete new genuine Yamaha seat
Polisport fork gaiters
Renthal Dakar bars
Symtec heated grips – heated pads that fit under the grips with two heat settings
Totally TTRs special long clutch and throttle cables made by Venhill
Hel braided front brake hose
Renthal R3 chain and (13/48) sprockets with chrome counter-sunk bolts on the rear sprocket
Wheel rims and hubs powder coated and re-spoked
Wheel bearings and seals
Mudguard brace
ProGrip wrap-around handguards and grips
D&D full graphics kit
Totally TTRs full sump guard (the best on the market!)
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
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.