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

I have had one of those days where I have made a catalogue of apprentice errors on an engine rebuild making a few hours work take a whole day 

a) dropped a gudgeon pin circlip into the sump whilst fitting a new piston. The first time since I remember that I didn't stuff a rag under the piston to prevent such a thing happening! I wasted half an hour fishing around with one of those extending magnet devices with no success so came in for a tea break thinking of maybe flushing the sump or splitting the cases  Trish took pity on me and agreed to hold a torch whilst I did some more fishing. After explaining what had happened and where the circlip possibly lay underneath the crank, she took the magnet and fished it out in less than a minute 

b) I then fitted the piston and as about to fit the head when I realised that, in my excitement, I had now fitted the piston back to front 

c) I was fitting a new cam chain so had the clutch cover off and managed to strip a thread putting it back on. No problem - soon helicoiled it and had the cover back on. 

d) realised that I hadn't adjusted the clutch play whilst the cover was off so off it came again to do that job 

e) bolted on the cams and started to adjust the valve clearances and managed to strip a cam cover bolt thread. No problem, out with the helicoil set again. Soon fixed that and bolted the cams back on.

f) realised that I hadn't torqued up the head bolts so off with all the cam gear again!

I was using a small torque wrench so take no responsibility for stripping the threads - they must have been damaged by the "previous owner" 

Well, I managed to finish the job with no further traumas and have packed up for the night. Fitting and testing it will have to wait until tomorrow. Maybe I will get Trish to supervise work tomorrow 

Brian

I would say that your story illustrates your patience and maturity, Brian. You seem to have addressed each set back appropriately and carried on. I think I would have thrown in the towel (and not under the piston) and given up. Any way, I hope hope that your following days are smoother.

Larry