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The TTR250 FAQ web pages -> TTR250 -> Projects and restorations -> 2000 model TT-R250M Build 4PX6 ''Rebuild nearly finished''
Post Info TOPIC: 2000 model TT-R250M Build 4PX6 ''Rebuild nearly finished''
barra8


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RE: 1999 model TT250-RLC Build ''Preview''
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I acquired the paint today Will be painting either the frame or swingarm (or both if i have time)

I am most impressed with the colour for the frame but still unsure about the swingarm (we''ll see) .

Well till then....Stay tuned. wink

................

Jarrah.



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barra8


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Not sure whether it's the three hours sleep i had last night or just a bad day but my plan was to primer coat & top coat/lacquer my swingarm. RESULT: Compessor blew up....spent most of the day trying to fix with no result.. Maybe i'm not so good at fixing compressors i admit biggrin

Hope tommorrow goes smoother than today. Buying a new compressor & trying again. Maybe tommorrow i will feel like i have acomplished something & not just gone backwards. To be honest i feel useless as the only thing i acomplished today was to set up the spray ''tools''.

This paint is turning out to be a ''Pain '' T no

Well better luck tommorrow i hope (fingers crossed )wink

....................

Jarrah.

 



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YAMAHA ROCKS!!!!!!

TTR250ACTIVE''BORED'' ADDICT!

Favourite quote: To be old & wise first you must be young & dumb!

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barra8


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1999 model TT250-RLC Build ''Rebuild started''
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Section 6: Spray painting

 

Yesterday was a very bad day as some might know from my last post. This was the aftermath from yesterday...no

Not a pretty sight smile Have since bought a new compressor & started with the primer coat. I used my little atomizing spray gun & was very happy with the results. The primer i used was AU $90.00 a litre but worth every drop & more wink

Forks...

Swingarm & components...

Just have to wait another 1 hour to top coat & clear coat them.

Stay tuned wink

..............

Jarrah.

 



-- Edited by barra8 on Tuesday 25th of December 2012 06:08:11 AM

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barra8


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RE: 1999 model TT250-RLC Build ''Preview''
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Top coat achieved...A little woried the clear might react with the clear coat that i have so best to wait 7 days for the paint to cure first.

This is the forks (without clear coat)

Now the swing arm & components..

Quite happy with the result smile

If the weather is good i will be spraying the frame tommorrow.

Stay tuned..wink

...........

Jarrah.



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barra8


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The weather was good to me today & managed to get a primer coat on frame & components. Once again i was most happy with the result. The primer im using rules!!!

BIG.. to the primer & spray gun & a little to myself for a job well done. wink

 

This was the result of primer coating the frame (something i really did'nt want to do as touching it up would have been nice & easy but not as good :)......

 

Tommorrow i will be top coating the frame if the weather is good.

Stay tuned wink

..............

Jarrah.



-- Edited by barra8 on Saturday 10th of November 2012 06:49:47 AM

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barra8


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domski1 wrote:

Good work jarrah, you soon will have the project finished then what will you do????? Really good work though and well documented.

 Thanks Mark (or chris :bad memory :),

                      Good question whats next??? Building spaceships? Building Rockets?? confuse I prefer getting to ride my project biggrin

I do have my car to finish though (although maybe not so interesting on here :)

........................

Jarrah.



-- Edited by barra8 on Saturday 10th of November 2012 07:50:45 AM

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domski1


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Good work jarrah, you soon will have the project finished then what will you do????? Really good work though and well documented.

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TTRfan


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Good progress Jarrah!

Are you going to rub down the primer before top coating? I have always found that difficult. It is all too easy to go through to the bare metal on the sharp edged parts - of which there are lots on the TTR frame no

Brian

PS Mark and Chris are really Adam wink



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barra8


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TTRfan wrote:

Good progress Jarrah!

Are you going to rub down the primer before top coating? I have always found that difficult. It is all too easy to go through to the bare metal on the sharp edged parts - of which there are lots on the TTR frame no

Brian

PS Mark and Chris are really Adam wink

 Giving it a light rub down,it has three coats so should be okay. Know what you mean about sanding it though & will be only lightly sanding so as not to rub the primer off.

ps. Mark,chris,adam what's the difference wink Okay maybe a little biggrin Glad i did not claim to have a good memory biggrin

.....................

Jarrah.



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barra8


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Had to do another primer coat as even though i made sure i got the edges (i spray all edges first) it needed it as the primer did rub off a little in places. Also the primer was drying out a little too much i relized after sanding. The reason for this is that it has been 27 degrees in the shade here for two days so quite hot.  I added more thinners to compensate for the heat. I also don't have a high temp thinner for the primer but i'm glad i do for the top coat aww . Still not sure whether i will spray the top coat today,may just get it A+ & start a fresh page in the morning ? confuse

I am once again impressed with the result & did manage to get a nice wet coat on so not alot of sanding will be neccessary. You may not see any difference from this pic but i can assure you that it has now had 4 coats wink....

..................

Jarrah.

 



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YAMAHA ROCKS!!!!!!

TTR250ACTIVE''BORED'' ADDICT!

Favourite quote: To be old & wise first you must be young & dumb!

My own: Your never too young to learn an old trick! :)

barra8


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Im so glad i gave it another good coat as it came up a real treat this time. The primer is amazing stuff & cannot give it enough credit.

Gotta go to work tommorrow so no updates for awhile. Instead of working on my bike i will be working on another truck yay (not)smile If the weather is good on thursday i will be top coating then as Wed i get my full bike licence through Qride.

Well.. have fun all wink

                           Jarrah.



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barra8


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It was cloudy this morning but it cleared up

This is base coat N1. Yamaha 0564 Deep Purplish Blue Metallic C (DPBMC)    

Will be spraying base coat N2. in ten min..Stay tuned.wink

................

Jarrah.

 

 



-- Edited by barra8 on Thursday 15th of November 2012 07:58:51 AM

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Favourite quote: To be old & wise first you must be young & dumb!

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barra8


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I won't have time to clear coat it today so maybe tommorrow afternoon i will finish it.

The light is'nt that good for taking pics but this is base coat N2.  Yamaha 0583 Deep Purplish Blue Solid E (DPBSE)

Will take some better pics tommorow in the light...

........................

Jarrah.

 



-- Edited by barra8 on Thursday 15th of November 2012 07:56:40 AM

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barra8


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I did end up getting the clear on but once again bad light. Will take more pics tommorrow.

Thats the frame done so onto the last coat for the forks & components tommorrow.

Stay tuned wink

...........

Jarrah.



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YAMAHA ROCKS!!!!!!

TTR250ACTIVE''BORED'' ADDICT!

Favourite quote: To be old & wise first you must be young & dumb!

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barra8


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New pics of my frame finished...

I will be uploading pics of the black sparkle paint i sprayed on the components soon...

Stay tuned wink

.........

Jarrah. 



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YAMAHA ROCKS!!!!!!

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Favourite quote: To be old & wise first you must be young & dumb!

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barra8


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This is a black acrylic paint with glitter dust in the clear coat. Turned out great aww

Tommorrow will be time to spray the engine.

Stay tuned.wink

.............

Jarrah.



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nikroc


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Stunning paintork...almost inspiring!!!!....shame Im a lazy git.

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barra8


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nikroc wrote:

Stunning paintork...almost inspiring!!!!....shame Im a lazy git.

 Cheers buddy,

                       Not sure what paintork means but anyways

...................

Jarrah.



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TTRfan


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Looking good biggrin

The exciting bit is when you start to bolt things back on the frame and you must now be at that stage wink

I confess to having several attempts at routing the wiring loom before getting it right disbelief

Brian

PS That's a heck of a cassette collection you have there Jarrah!



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barra8


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TTRfan wrote:

Looking good biggrin

The exciting bit is when you start to bolt things back on the frame and you must now be at that stage wink

I confess to having several attempts at routing the wiring loom before getting it right disbelief

Brian

PS That's a heck of a cassette collection you have there Jarrah!

 Thanks Brian wink 

I have done the wiring many times but know what you mean-before i ''worked it all out'' it was a nightmare smile

Yeah quite a few i guess-hard to chuck out old stuff like that smile

I am still in the process as we speak of preparing the engine for a light coat of silver paint- not sure if i'll like the colours i have but i'm pretty sure to find one i like wink

......................

Jarrah.

 



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YAMAHA ROCKS!!!!!!

TTR250ACTIVE''BORED'' ADDICT!

Favourite quote: To be old & wise first you must be young & dumb!

My own: Your never too young to learn an old trick! :)

barra8


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Finished my engine today. I could not match the OEM colour without going to extremeties so i decided to make it custom.

 I was very happy with the results but the pics do it no justice at all. no

This is the High Temp VHT Universal Silver coat..

 

This is after a clear with Sparkle Dust added...

 

I will still have one more clear with sparkle to do on the swing-arm ect. I will not be able to do this until it gets back from the graphics place though (early next week).

Still have a few more black coats to do also with the sparkle but nearly done now.

.....................

Stay tuned..wink

Jarrah.

 



-- Edited by barra8 on Friday 16th of November 2012 06:11:37 AM

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TTR250ACTIVE''BORED'' ADDICT!

Favourite quote: To be old & wise first you must be young & dumb!

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TTRfan


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Shiny biggrin



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BM Steve


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Hmmmmm, Sparrrrrkly



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2004 TTR250 - Highway Dirtbike Hand Guards, 38mm Bar Risers, D606 Front & Rear, Opened up Airbox with Twin Air Filter, Re-jetted Carby, B+B Bash Plate & Frame Guards, DIY 3mm Alloy Tail Tidy, 14/47 Gearing.

 
barra8


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BM Steve wrote:

Hmmmmm, Sparrrrrkly

 
TTRfan wrote:

Shiny biggrin

Thanks for the feedback fellas

I was most happy with the result. The pictures do my paintwork no justice but atleast you can see it a little.

........................

 


Jarrah.



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YAMAHA ROCKS!!!!!!

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Favourite quote: To be old & wise first you must be young & dumb!

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barra8


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Was a bit too busy to update this but i did get a fair bit done. Mainly small parts that have been sprayed black with the sparkle. My living room looks like a mechanics workshop but the parts are nice to look at. I'm glad i don't have a GF wink

There is more parts than this but you get the point i think smile

I will upload what i did today soon. (or tommorrow ?)

................................

Stay tuned...wink

Jarrah.

 

 



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YAMAHA ROCKS!!!!!!

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barra8


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I will take better pics tommorrow but heres an okay one of my carb...

Stay tuned wink

Jarrah.

 



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barra8


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I had a little problem with one fork. It started as just a little problem of a deep scratch that the primer coat could not get out. I decided to be lazy & bought spray putty....BIG MISTAKE!!no

The spray putty reacted with my primer & i then had to take it all back to bare metal (just about). Then primer coated it....

For the mark this time all i did was use a cotton bud & dabbed a blob of primer on there..This was the mark that caused all the trouble.... 

Waiting on the primer to dry & then a sand back will be required.

I will be so close to finishing by the end of today. Can't wait as i look like i have just crawled out of the tin & wiped myself a little wink

When the paint is done i will have to wait a week before assembly for the paint to cure blankstare Should be worth the wait though.

...........................

Jarrah.



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YAMAHA ROCKS!!!!!!

TTR250ACTIVE''BORED'' ADDICT!

Favourite quote: To be old & wise first you must be young & dumb!

My own: Your never too young to learn an old trick! :)

barra8


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I started off painting the tripple tree (clamps) silver but was'nt happy. Decided to go black sparkle & glad i did. Results below...

Will be spraying the forks this arvo....Stay tuned wink

...............

Jarrah.

 



__________________

YAMAHA ROCKS!!!!!!

TTR250ACTIVE''BORED'' ADDICT!

Favourite quote: To be old & wise first you must be young & dumb!

My own: Your never too young to learn an old trick! :)

barra8


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Finished the forks & most happy with the result (as usual :) ...

 

One with the flash to show the sparkles (athough you can see it alot better in the sun ) ...

Just have to top coat my swingarm when it gets back (hopefully tommorrow).

Waiting for the paint to cure 7 days may be the hardest part of the re-build :)

Stay tuned..wink

...........

Jarrah.



__________________

YAMAHA ROCKS!!!!!!

TTR250ACTIVE''BORED'' ADDICT!

Favourite quote: To be old & wise first you must be young & dumb!

My own: Your never too young to learn an old trick! :)

barra8


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1999 model TT250-RLC Build ''Rebuild started''
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Section 7: Modifying the airbox

I was not happy with how Mr YAMAHA had the airbox installed as it was very tight & would have rubbed on the frame causing my beautifull paint to come off no Something had to be done about it. I decided the easiest way was to trim it down a little at the top so it has space between the frame & airbox. This was the piece i chopped off (below)

 

More had to be taken off it & the other side trimmed aswell.

I now have room there & makes it easier to install (see below)...

 

Still have to glue rubber to where the seat sits against the frame to stop it taking my paint off.

ps. I did'nt relize it was this dirty until i took a pic lol :)

......................

Jarrah.

 


 

End of modifying the airbox

>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>



-- Edited by barra8 on Tuesday 25th of December 2012 06:11:04 AM

__________________

YAMAHA ROCKS!!!!!!

TTR250ACTIVE''BORED'' ADDICT!

Favourite quote: To be old & wise first you must be young & dumb!

My own: Your never too young to learn an old trick! :)

BM Steve


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RE: 1999 model TT250-RLC Build ''Preview''
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Your not even going to want to take it out of the shed when your finished biggrin

I like my scruffy and scuffed old girl, I don't even feel I have to wash it  unless I'm doing a service  yawn 

Just a quick hose off to make sure everything is still bolted on where it's suppost to be

You should see my Ute, it's got moss and mildue growing on it,  I really should give it it's annual bath and polish no

Steve



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2004 TTR250 - Highway Dirtbike Hand Guards, 38mm Bar Risers, D606 Front & Rear, Opened up Airbox with Twin Air Filter, Re-jetted Carby, B+B Bash Plate & Frame Guards, DIY 3mm Alloy Tail Tidy, 14/47 Gearing.

 
barra8


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BM Steve wrote:

Your not even going to want to take it out of the shed when your finished biggrin

I like my scruffy and scuffed old girl, I don't even feel I have to wash it  unless I'm doing a service  yawn 

Just a quick hose off to make sure everything is still bolted on where it's suppost to be

You should see my Ute, it's got moss and mildue growing on it,  I really should give it it's annual bath and polish no

Steve

 Sounds like you have better things to do than (bloody) mechanics smilesmile

I have been joking to my mates that when it's finished i will be hanging it on my wall for an (big) ornament biggrin

......................

Jarrah.



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YAMAHA ROCKS!!!!!!

TTR250ACTIVE''BORED'' ADDICT!

Favourite quote: To be old & wise first you must be young & dumb!

My own: Your never too young to learn an old trick! :)

barra8


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The seat would have rubbed on the frame aswell....Mr Yamaha should have had this in mind before building it no but anyways hmm

The airbox had to have another mod so it did'nt ruin the frame once again.blankstare

Not hard to do though just install & mark it with a pencil,then take it off & cut with a stanley blade.wink It actually looks like it was built like that (i wish :).

This is the only thing i have found on a few seats now to protect the frame. (matteress foam disbeliefdisbelief)

I will be using foam that i got from a box (thick packing  foam:).  It is alot better & will do the job of protecting the frame. Four small peices of packing foam & one large peice should do fine. You can see where it rubbed the frame down to bare metal causing rust.( It was'nt my bike but my frame was scraped up in all these places).

You should be able to see the four rust spots & pethetic mattess foam that is suppose to be protecting the frame.(but is'nt)...

 

 

Will be uploading a decent pic of my engine next...Stay tuned..wink

........................

Jarrah.



-- Edited by barra8 on Friday 23rd of November 2012 01:26:32 AM

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YAMAHA ROCKS!!!!!!

TTR250ACTIVE''BORED'' ADDICT!

Favourite quote: To be old & wise first you must be young & dumb!

My own: Your never too young to learn an old trick! :)

barra8


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1999 model TT250-RLC Build ''Rebuild started''
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-- Edited by barra8 on Tuesday 25th of December 2012 06:26:45 AM

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YAMAHA ROCKS!!!!!!

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Favourite quote: To be old & wise first you must be young & dumb!

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TTRfan


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RE: 1999 model TT250-RLC Build ''Preview''
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Looking good biggrin



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barra8


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Thanks Brian,i'm sure there is many watching this thread but not many share there opinion. Good to know a few like it so far though

............

Jarrah.



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YAMAHA ROCKS!!!!!!

TTR250ACTIVE''BORED'' ADDICT!

Favourite quote: To be old & wise first you must be young & dumb!

My own: Your never too young to learn an old trick! :)

barra8


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GYT-R Air filter installed,very easy,still have to buy the Foam kit though...

More to come...Stay tuned wink

.................

Jarrah.



-- Edited by barra8 on Friday 23rd of November 2012 01:20:47 AM

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domski1


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Great work jarrah! I am sure lots of people are watching this thread and will appreciate all the knowledge that has gone into it!

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barra8


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Thanks Adam! Glad my thread is usefull & is a welcome sight on the forum. Cheers all that have supported my along the way.

.................

Jarrah.

                        



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YAMAHA ROCKS!!!!!!

TTR250ACTIVE''BORED'' ADDICT!

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barra8


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The frame is cured now so i decided to start the re-build. I was going to make a separate thread for this but i may aswell use this thread.

This is with the airbox & wiring harness installed...

Will be slowly bolting bits on today (as i dig them out of my haystack :)

Stay tuned.wink

...........

Jarrah. 



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YAMAHA ROCKS!!!!!!

TTR250ACTIVE''BORED'' ADDICT!

Favourite quote: To be old & wise first you must be young & dumb!

My own: Your never too young to learn an old trick! :)

barra8


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2000 model TT-R250M Build 4PX6 ''Rebuild nearly finished''
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Section 8: Wiring & cable routing

 

Have a bit of time to spare as i can't do alot until i install the motor. I thought i would upload pics of the wiring route. It actually took longer to make this post than to install but anyways smile

The pics should say all but start by bolting on the ignition barrel...

 

Then bolt on the ressister/regulator...

 

 

After that put the wiring in the two clips (near regulator). Then move onto the clip in the pic below...

 

The wiring just goes on the inside of the frame for the starter relay wires....

 

 

 

 

Now it goes down to the brake light switch..

Now moving onto the top rear (right) section the wiring goes under the frame & gets cable tied along with fuel lines ...

 

Now onto the next clip (i may want to touch up where the wire goes with a cotton bud??:)...

Last pic for this side...

Now onto the left side...

The stator coil (ac magneto) wires go in with the wire below

 

Getting near the stand switch now...

 

Onto the cdi box...

Continued on from the cdi plug...

 

This is now the end of the wiring harness & the start of the rear fender wiring/blinker ect....

Start of rear fender wiring & end..

 

 

 

To show how the AC magneto & clutch switch wires go...This is with boot installed...

This is without...quite simple...

Onto the headlight..I put it over the speedo assembly bracket & cable tied it....

 

 

 

Cable tie any loose wires & route the wires to the headlight (easy if you have somewhere for it to go.... unlike me :)

Okay...Pat yourself on the back wink

 

..................

Jarrah.

 

 



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nikroc


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RE: 1999 model TT250-RLC Build ''Preview''
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Enjoying the progress Jarrah. Im just putting my air box and card back in mine..I look forward to seeing where you route the carb plumbing...

Re the various 'contact 'points of things like frame/air box/seat...have you considered using pieces of old inner tube as sleeves ?..these could be either glued into position or cable tied...

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barra8


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nikroc wrote:

Enjoying the progress Jarrah. Im just putting my air box and card back in mine..I look forward to seeing where you route the carb plumbing...

Re the various 'contact 'points of things like frame/air box/seat...have you considered using pieces of old inner tube as sleeves ?..these could be either glued into position or cable tied...

 I did glue rubber at the start to the side. You should be able to see this from the pic below. It is useless doing that though as rubber will not help & if anything only assist in rubbing the paint off. A gap between the airbox was needed. You will get to see the wiring & fuel line route fairly soon as i'll be putting the engine in in the next few days.

Ps. thanks for the feedback.

REMINDER TO ALL: IF ANYONE HAS QUESTIONS OR WOULD LIKE TO SAY SOMETHING ABOUT ANYTHING PLEASE FEEL FREE TO DO SO! wink



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YAMAHA ROCKS!!!!!!

TTR250ACTIVE''BORED'' ADDICT!

Favourite quote: To be old & wise first you must be young & dumb!

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barra8


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1999 model TT250-RLC Build ''Rebuild started''
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Taped up & ready to install the motor tommorrow biggrin Looks alot like a tiger ready to pounce but does'nt have the guts to hahasmile

Stay tuned wink

.................

Jarrah.


 



-- Edited by barra8 on Tuesday 25th of December 2012 07:26:41 AM

__________________

YAMAHA ROCKS!!!!!!

TTR250ACTIVE''BORED'' ADDICT!

Favourite quote: To be old & wise first you must be young & dumb!

My own: Your never too young to learn an old trick! :)

barra8


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It took me longer than i thought to round up a mate to help but in the end it is in with no dramas..

If doing this make sure to keep the clutch actuator lever away from the frame (taped up) as this could cause trouble...

Time to start bolting parts on aww

.....................

Jarrah.



__________________

YAMAHA ROCKS!!!!!!

TTR250ACTIVE''BORED'' ADDICT!

Favourite quote: To be old & wise first you must be young & dumb!

My own: Your never too young to learn an old trick! :)

barra8


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nikroc wrote:

Hi...any chance of you taking a picture(and posting it) of the right hand side of the bike?....I cant remember what goes where...

 I don't have much on the bike atm... What things are nessesary for you to see??

..................

Jarrah.



-- Edited by barra8 on Tuesday 27th of November 2012 07:53:36 AM

__________________

YAMAHA ROCKS!!!!!!

TTR250ACTIVE''BORED'' ADDICT!

Favourite quote: To be old & wise first you must be young & dumb!

My own: Your never too young to learn an old trick! :)

barra8


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I have decided to do everything methodically because it will help in future for some people (maybe even myself).

To install the airbox...

This can be a very tight fit if not modded as decribed above athough if you want to continue....Warning: You will most likely scratch the frame having to ''cram'' it into place.

Make sure you have the ''Stay frame'' off first..

Now go to the RH side and bolt the last one...

Airbox installed.

Now for the frame stay...

Put the bottom side in first then gently guide it in.Be carefull when you take it in & out as you can take the paint off easy.

Once in put the bolts in where shown in pic with red arrows...

If you look above you will also see i have installed the chain roller. To do this is easy,just make sure the bearing is to the outside of it. (closest to nut &washer)

Will be uploading more shortly...Stay tuned wink

..................

Jarrah.


 



-- Edited by barra8 on Tuesday 27th of November 2012 08:59:38 AM

__________________

YAMAHA ROCKS!!!!!!

TTR250ACTIVE''BORED'' ADDICT!

Favourite quote: To be old & wise first you must be young & dumb!

My own: Your never too young to learn an old trick! :)

nikroc


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Posts: 20
Date:
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Hi...any chance of you taking a picture(and posting it) of the right hand side of the bike?....I cant remember what goes where...

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nikroc


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THE BATTERY BOX,STARTER SOLENOID ETC...I WAS TRYING TO REBUILD MY TTR 600 AT THE SAME TIME..MANAGED ONE BUT NOT THE OTHER...opps,sorry bout the capitals

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TTRfan


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nikroc wrote:

THE BATTERY BOX,STARTER SOLENOID ETC...I WAS TRYING TO REBUILD MY TTR 600 AT THE SAME TIME..MANAGED ONE BUT NOT THE OTHER...opps,sorry bout the capitals

Rather than hijack Jarrah's thread Nic, I have started a new one with some pics to show how things go back together - see here

I can't find a good pic of the airbox side immediately but there is bound to be one in my library somewhere!

Brian



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