I have partially stripped down my `new` 2003 bike today to get an idea how it all goes together. While I was at it I cleaned all the electrical connectors and filled them with Dielectric grease to keep out moisture in the future. The spark plug recess had a lot of dry mud in it and it took a fir bit of fiddling followed by a vacuum clean to get it all out so I could remove the spark plug for inspection. Is this normal? If so, what happens if you need to remove the plug when on a run? There is no way you could get it clean enough with the tools that one would normally carry.
I am just off for a first little ride to see if anything else needs sorting out. The bars a re a bit bent so I have a set of Renthal 613 on order and will be fitting them with a set of 2" risers and longer cables in due course.
There are a couple of threads about the spark plug access. Martyn (cubber) used to have a sponge round the top of his plug that was flush with the top of the engine block, but he gas since decided that it was trapping moisture in the recess and rusting the plug. He now has a home made flap of rubber or plastic that sits over the plug with a hole or slot for the lead. Apparently this works well.
I hope you get a chance to put some info about the mods you've got planned, I'd be interested to know how easy the bar risers and extended cables are to fit. It'll be nice when you've got it all just as you want it :)
Pete
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Pete Brown
Keighley, West Yorkshire
'94 Yamaha TTR 250 Raid (with Open Enduro headlight, grrr...)
I had a look at the routing of the cables whilst I had the bodywork and tank off and it looks like a straightforward job. I have just been out for a short spin. The bike takes a few goes to start and it is a bit hesitant and `on/off`at low throttle openings. It pulls fine higher in the rev range. It ticks over fine when warm. Any ideas what could be causing the low rev issue? I guess I should check the valve clearances to make sure they are in spec. I will do that when I have the tank off to fit the cables when they arrive.
As a pure guess you could try cleaning your carb, as the different response through the rev range could be accounted for by one of the jets being gummed up, but as I say that's a pure guess
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Pete Brown
Keighley, West Yorkshire
'94 Yamaha TTR 250 Raid (with Open Enduro headlight, grrr...)
but the sponge idea keeps the damp in and makes the plug rusty. 
