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

You can't keep a good bloke down, can you.

I think Brian's got too much time on his hands and can't stop fiddling with TTRs. 

Trouble is, Brian, you are to good at it and put the rest of us to shame. You're too dynamic, there's no stopping you.

In reality, it all boils down to the fact that I'm really jealous.

Keep up the good work.

Martyn

Took me a while but the forks, yokes and gaiters have been cleaned up and fitted together with the speedo. Must remember to torque up the steering head nut when I get the wheel in!

Despite multitudinous interruptions, and Totally TTRs getting very busy, I have managed to do a bit more to the current TTR resto.

I have refurbished the swing and linkage arms and fitted them. I was very lucky and only had to change the lower shock bearing - and that was more of a precaution than anything else. However I needed to fit a new chain slider to the swing arm as the old one had been chewed through and the chain would have soon been attacking the swing arm bearing cap.

I won't fit the swing arm decals until later on so I don't damage them whilst working on the bike.

I remembered to put the carb breathers down behind before fitting the swing arm this time - a lot easier than trying to do it afterwards.  

I had already put the carb through the ultrasonic cleaner so it just needed a final check over and putting back together with a new gasket and O rings.

It is a lot easier to fit the carb and the breather hoses before the shock absorber as you have room to work.

I hope to fit the shock absorber, battery and air boxes tomorrow if no more interruptions 

Kenny R wrote:

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I spy, two hammers, an adjustable wrench, pair of mole-grips and a scraper.

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All needed to sort out unwanted visitors - and a reluctant linkage bolt 

Let's hope it's not too "shocking" for you when it lights up, Brian.

If you add a "brolly hook" it will be prepared for the current weather, pimply sissing down at the mo.

Martyn

I got the rear wheel in but after tightening up the axle it showed the rear wheel bearings to have some play so out it came and I fitted new bearings and seals. The spacers were in good condition and not ridged (which lets water by the seals) so were able to be re-used. 

I also fitted the airbox and a freshly cleaned and oiled air filter which then allowed me to fit back the CDi so, with a petrol tank on, the engine should theoretically run 

However quite a few more fiddly bits to do first!

As in quite a few of the TTRs that I see the front hose was damaged where it slides up and down against the white plastic guides on the yokes so needed replacing. I wasn't looking forward to doing the job as it can be very difficult to bleed the front brake and, also, I usually end up getting covered in brake fluid 

However, this time I was lucky and the brake bled fine 

I must say that the Venhill s/s replacement hose is a lovely bit of kit, very well made and fits beautifully.

Next little job is to repair and fit the front brake light switch. I also have the rear brake light switch, brake lever and footpegs to fit. After that its just the rear mudguard, seat, petrol tank and side panels to sort out.

Brian

RHS now complete with exhaust guard, footrest, kickstart and footbrake lever fitted. But, looking at the pic, I now realise I need to sort out some frame guards 

Headlight and handguards are on. I need to sort out a decal for the headlight and tighten the handguards when I have ridden the bike and am happy with their positioning. I also remembered to fit the speedo cable this time Martyn 

I need to torque up the sprocket nut and fit the sprocket cover and the LHS will also be finished. 

Nearly there!

Brian

I was watching and waiting for the mention of speedometer cables, Brian.

Wisdom obviously comes with age and maturity - I'm still waiting for mine!

You certainly turn out a decent product, I must say.

TBH your product is better than Mr Yamaha turned out At least yours are complete with proper guards and frame protectors.  

Martyn

Sprocket nut torqued up and tab washer knocked over. I could then fit the sprocket cover after which the frame guards.

Getting close to showing the TTR daylight 

Thanks for the kind words Ian!

I have now fitted a complete set of Enjoy Graphics so the TTR looks better all the while.

However, there has been a slight delay in completing the project as, having got the TTR all back together and getting it taxed and MOTd, I set about changing the oil and filter - see here. However, I was unlucky as, despite using a torque wrench, the bottom filter bolt stripped its thread 

At this point I had to leave the TTR as Mrs TTR had booked us a short break in a wet & windy St Ives. We arrived back home yesterday evening feeling a bit knackered after a couple of days walking up and down the steep streets of both St Ives and Port Isaac (where Doc Martin is filmed) so didn't get back on the TTR until today.

Anyways up, the stripped thread has been repaired and the TTR all back together. I need to apply a few finishing touches and will then take some pics and post them up. I used the opportunity to do a "show and tell" as it's not an uncommon issue. See here

It got very cold in the workshop later this afternoon so I confess to packing up early so the finishing off will have to wait until tomorrow - grandsons allowing....

Brian 

All done! Just need to put a few miles on it now to make sure the engine is as good as I think it is and check that I have remembered to tighten everything up properly!

It's very easy to be distracted on a rebuild and put nuts and bolts on finger tight with the intention of going back later to torque them up properly - but then forget 

I was speaking to an experienced motorcycle mechanic and engineer the other day and he found the answer is always to tighten up right away - good advice that I will take on board for the future 

Very nice work Brian (as usual).

I like the colour scheme!

Jarrah

buffalo4 wrote:

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 Please start the pics of this new one Brian

Cheers Ian

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I think I would be in danger of boring forum members Ian! Much of the work will be exactly the same as this finished project (for example see pic below of progress to date)  but if I hit any snags or there is something new that I have to do then I will post it up. Most of it is just painstaking cleaning of parts etc.

The new project TTR was first registered in January 2006 which is the newest I have had to work on. I bought it back in Feb 2011 and it has been stored under cover until recently. 

I have a note that I couldn't start the engine and, at the time, thought it was due to low compression. So this one might be a bit more interesting as I will enjoy some engine work for a change!

Must say, thats another fantastic examlple.

oshanrube wrote:

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hi, im new to the whole DIY thing, about 6 months ago when i got the bike i tried painting the handle bars etc and not it seems to be more rusty,

is there a way to paint the bars?
add primer and stuff? if so what are the steps?

how to paint the heating parts (silencer cover, engine cover, calipers)?

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I use silver steel wheel aerosol paint on the parts most susceptible to scratching or wear such as swing arms and lower fork legs. 

Regarding the exhaust guard, etc, it is surprising how much heat ordinary car aerosol paint can take. Give it a try!