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Post Info TOPIC: Greetings from California.


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Greetings from California.
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Hello all, my name is Mingle I am a California resident , and love the idea of getting around town with little fuel and having a blast doing it!.. So a few months ago I scraped up all my pennies and bought a clapped out 01 ttr250. for the right price. but I bought it knowing I would refurb and rebuild this bike totally, and supermotard it. 

THE BAD:

It had squeaky suspension bushings

leaking F&R shocks

brake pads with 1/2 mm of lining  on them

scratched plastics 

worn clutch, worn sprockets

infamous bang while stopping the engine 

oil leaking barrel and other oil leaks/seepage 

fmf muffler with all bolt holes ovaled out

previously repaired subframe

cloged carb, and striped drain screw

worn linkage, swing arm, and rear wheel bearings

faulty wired turn signals

some wrist pin or con rod tap noise

and a major thirst for the thickest oil available

THE GOOD:

It is Plated and street legal

new dot tires

aftermarket "Vortex" aluminum air box

aftermarket FMF pipe

Derestricted (.)

and a rumor that it was, "bored to the biggest size"

 

And for a few months I was riding this beast all over town going to the mountains where I live and down to the beaches and everywhere in between, all with a koolaid smile! biggrin I found a seller that had a fresh ttr 250 with bent valves, so was off to gather some parts, first on the list was a starter motor then, rear shock, front wheel, rear fender, and some other odds and misc. I scored a great deal.

A short time latter  I found another seller parting out a 00 yz125 so off went the USD forks ! and onto mine. I had to make a sleeve spacer and find a longer axle to make it work.

also using good OL' Craigslist i found some 17in 3.5in/4.5in excel takasago rim hoops for the supermoto conversion latter on.

but after meticulously  checking before every ride and refilling the case due to a major oil leak, I decided to finally take the plunge on the rebuild. 

I had a buddy of mine help in stripping the bike of its motor

after cracking that sucker open I confirmed the previous owners word of it being the popular 325 kit from thumper racing. 81mm bore is unheard of!!wink

but.. the rings were bad it had scratches on the piston skirt and sleeve, and a abnormal ammount of side to side play in the conrod/crank joint. also very leaky valves no

so I went through the carb and found it to be in similar condition. now it was time to make a parts list, and OH BOY was this going to be expensive!

I got a hold of travis @ thumper racing and ordered the piston kit and sleeve.

then  got a hold of chaparal racing and ordered all oem carb parts, con rod bits and cam chain (most of it being on back order from Japan)

I logged onto flebay and bought a starter gear, one way sprag clutch, gasket set, fork seals, clutch disks, skid plate, K&S mirrors, rear hub, LED signals, allballs crank bearings, jets, clutch holding tool, and front sprocket, work shop manuel all for super duper playa prices wink but every thing add up so quickly.

the same buddy that helped with the tear down recommended a machine shop so i will be getting the sleeve pressed in, bored, honed, for 100 bucks

at the same time we will be doing a three angle valve job + head porting biggrin

I found a bike shop that will rebuild the crank for 45 bucks labor.

come monday or tuesday i will have pictures and more info to come, i love this site (been trolling for a while) and you guys are cool. hope you like the intro.


ttr250.jpg



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Welcome to the TTR land, Mingle.

It sounds as if you're experiencing the BAD side first, I hope the GOOD side shines brighter (and less expensive) for you. aww

Please keep us all posted on the progress, together with pictures.

Martyn



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Budleigh Salterton. Devon



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Welcome from another "state-side" TTR rider. Mine is also street legal, though MUCH easier to do here in Vermont. From what I've read, getting one already legal in Cali. was a real score.

Curious about your fork conversion & also your aluminum air box.



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NEK (Almost in Canada)

VERMONT USA



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Welcome to the best site for TTR owners ever mingle  handshake.gif

                                                                                        Good to see new owners joining,congragulations on joining .smileNice bike Btw

 

You will find some really usefull info on the boards,also check out the FAQ eg. http://www.ttr250.com/ if your bored or stuck with something.confuse Otherwize ask a question on here and your sure to recieve an answer.

Don't forget to check out Brian's site

If you want cheap oem parts check out this site eg. http://www.boats.net/parts/search/Yamaha/Motorcycle/parts.html or www.powersportsplus.com if you have'nt already.

 

 

Jarrah.



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thanks TDVT, and Cubber, for the welcome.
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I just keep telling myself its going to be worth it in the end. I was definitly experiencing the GOOD before the BAD, I had been riding it for almost a couple of months before the tear down. improving on the wheelies, practicing turning, and enjoying every minute of it. Everwhere I rode I had a smile. Also the expense is about half of a newer Used supermoto which would have unknown flogged miles, or mantinence intervals.

 

As far as the Vortex aluminum air box, it came with the bike, but the build quality is stout!

And the front fork conversion is somthing I did myself, I found a 2000 YZ125 being parted out, I accuired both fork legs, upper and lower triples with lower bearing, and the axle<(not needed)

I reused the yz lower bearing and reused  the ttr upper bearing. I had to dremel the threads off a star nut as a spacer and assembly went right in with no play of any sort.

now the axle issue was a little tougher I had to go to a local moto junker to find a 15mm axle that was 1in longer than the ttr with a matching nut, and a clampable shank/head of 20mm

now on the yz fork legs left side is 20mm and the right side is 25mm iicrc.

so a spacer was needed, I got crafty and tuned my dremel chuck into a lathe and i sanded down a spacers outside diameter down to the correct size of 25mm. ( im running my axle backwards from traditional) then hack sawed hot dog style to allow the bushing to flex slightly it measures: inside dia:15mm, outside dia:25mm, length:36mm

then it was fitting washers and bushings to center the rim and rotor.



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RE: Greetings from California.
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Hi Mingle and a belated welcome to the forum!

Some interesting modifications you are trying smile

Could I ask a big favour please and that is to get the dimensions of the sleeve from Thumper? 

Inside and outside diameter and wall thickness plus height of the sleeve.

Size of the lip at the top would also be good biggrin

The piston doesn't look like a Wiseco. What make is it?

Looking forward to seeing the rebuild progress - lots of pics are always good wink

Brian



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I finally finished the engine rebuild. also made a brake snake, and Red bull reservoir cover, and bought a used Cortech tail bag



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Also getting ready to motard it with 17s



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LRJ


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It shows very well at this point, I'd say. How does the engine feel after the rebuild? I bought my '00 a year ago, but it was in pretty cherry shape, fortunately. I don't have the knowledge or skill to attempt what you have done.

Larry

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Central California, U.S.



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The bike looks great! I didn't think to ask earlier about the TTR caliper bolting up to the YZ forks. Direct fit or did you fab an adapter?

Please keep us up to date with your impressions as your get some seat time.



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NEK (Almost in Canada)

VERMONT USA



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Am I also seeing a kickstarter on there? If so, something you added?



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NEK (Almost in Canada)

VERMONT USA



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Larry, thank you she feels amazing... more oomphf on the bottom end and pulls like a train. Not really any increase in vibrations. and the wrist pin / cam chain/ valve noise is gone. also no more bang when you cut the engine.



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Ok so I forgot that I swapped to the yz caliper and bracket. while using the TTR master cyl. 

the fork posts where the caliper bracket bolt on, are different distances between the TTR & YZ

Hence keeping the YZ fork with the caliper & bracket. This will be changing very soon though.

As for the kick starter, it was equiped by the previous owner, but I seem to be having an issue with it ever since the rebuild.  Every time I try to "kick" it over, it feels as if its turning the starter gears and starter motor, along with spinning the engine. This results in not enough rotation speed to actually get the engine to fire up.confuse



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