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

jasparach · Senior Member

1996 white ttr

Cubber · Super Guru

It looks like you've hit a lull in suitable answers, John. cry

I shudder to think what I would do if my spring return post broke, but yes, full gasket sets can be obtained with which to rebuild your engine. smile

If you look at this supplier BOATS you will be taken to an American dealer from whom bits can be ordered and shipped direct to your door. wink

Martyn

jasparach · Senior Member

Hello Martyn, thanks for that, i will get on to them and see what they have and as for
the spring return post it was disappointing to say the least when it happened,
but not to be defeated i made an aluminium block that holds it in place
when the right hand engine cover is on but if the clutch needs any work
it will need to be set up again, but i got me back on the lanes again
and has worked great ever since. Now that i have the spare engine cases
i can think about rebuilding the entire engine. Many Thanks.

TTRfan · Super Guru

jasparach wrote:
my question is do i need anything special in the way of tools to remove the crankshaft from mine to refit to the new crankcase when rebuilding.
Can i buy a set of seals and gaskets together as opposed to individually to rebuild the engine. Any help and pointers in the right direction would be great and to know what to look out for as I am going along.
Many Thanks
John

Hi John

I hope that some of the guides here may help you - http://ttr250.activeboard.com/t43766844/simple-step-by-step-pictorial-guides/

Plus there is quite a bit of info on engine strips and rebuilds on these threads:

http://ttr250.activeboard.com/t43731716/modernising-a-1993-yamaha-ttr250-open-enduro/

and

http://ttr250.activeboard.com/t43805944/ttr250-fitting-a-325cc-big-bore-kit/

No special tool needed to remove the crank but it might need some friendly persuaion with a hide hammer wink

I have not found a cost effective full repair gasket and seal set although I am sure they are available - somewhere! To be honest, all you really need are the cylinder head and base gaskets, maybe the clutch and generator cover gaskets if they are damaged - usually they come off on their cover in one piece. Unless the seals are leaking, I am not sure that I would replace them.

Hapy to help with any questions as you go along biggrin

Brian

jasparach · Senior Member

Hi Brian, thanks for the time and the information, yes you are probably right about
the seals, i can do them as needed. I have already done a Yamaha WR 200 2stroke
rebuild as in spliting the cases and putting it back together so the gears and things
i will find my way around, it's just the head work and all that on the 4stroke is a lot more
involved than the 2stroke. I have downloaded the workshop manual from the site so i have
that to go from. By the way off topic good work on the 93 open enduro modernising job,
brilliantly informative.

John

TTRfan · Super Guru

jasparach wrote:
Hi Brian, thanks for the time and the information, yes you are probably right about
the seals, i can do them as needed. I have already done a Yamaha WR 200 2stroke
rebuild as in spliting the cases and putting it back together so the gears and things
i will find my way around, it's just the head work and all that on the 4stroke is a lot more
involved than the 2stroke. I have downloaded the workshop manual from the site so i have
that to go from. By the way off topic good work on the 93 open enduro modernising job,
brilliantly informative.

John

Thanks for the encouragement John - much appreciated biggrin

Regarding my project, I am sitting here playing keyboard warrior as a bit of displacement activity coz the next job is to rebuild a pair of forks - not my favourite job

Brian

jasparach · Senior Member

One needs a bit of thinking time when tackling a job that is involved and fork rebuilding
is definitly one of those! Brian, are blue plastics hard to come by as i would like to
do the same to my white ttr, i bought a 2005 ttr with 4k miles on 3 weeks ago
and like the look of it and was thinking of doing the white one the same, having said
that i liked the look of a white one that you had done with a new set of graphics
and that looked fine, probably a cheaper option i guess to go with new graphics and tidy
it that way.

John