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

bbarfield · Veteran Member

Header pipe removal

TTRfan · Super Guru

Header pipe removal can be a challenge. There may be a knack but I don't think I have it and, judging by the gouges in the frame downtubes I have seen, neither do a lot of other owners!

I recollect someone saying to remove the front engine mount but can't vouch for it.

Not all header pipes are the same as the last few I have fitted went on no problem.

Anyone else help Brandon out here???

Brian

TT-R250M · Super Guru

TTRfan wrote:
Header pipe removal can be a challenge. There may be a knack but I don't think I have it and, judging by the gouges in the frame downtubes I have seen, neither do a lot of other owners!
I recollect someone saying to remove the front engine mount but can't vouch for it.
Brian

Very good Brian,

You do in fact have to remove the LH engine mount.

2013-12-14 20.06.20.jpg

Jarrah

Cubber · Super Guru

Don't alarm the poor lad. disbelief

The engine mounts only need removal if you're taking the head off or the engine out - not touched for exhaust removal.

To remove just the exhaust pipe entails nothing more than removing two nuts and washers from the cylinder head fixing and separating the pipe from the silencer.

Of course, if the pipe hasn't been removed and the bike's done a few miles then things will be reluctant to move, but patience, wangling and judicious force will dislodge the pipe from the head.

It would be best to remove the silencer to get proper access to the pipe but there's no need to unfasten the engine/frame fixings to get just the pipe off.

Be careful of the gasket ring between pipe and exhaust port if you want to reuse it. wink

Judicious force means waggling the pipe back and forth/up and down taking extreme care not to disturb the blue paintwork of the frame. smile

Martyn

Bugeye_bob · Veteran Member

Whip the tail pipe off makes the job much easier, it allow you to just do the up and down twist with out trying to pull it off the studs until the seal has been broke.

TT-R250M · Super Guru

Cubber wrote:
Don't alarm the poor lad.
The engine mounts only need removal if you're taking the head off or the engine out - not touched for exhaust removal.
To remove just the exhaust pipe entails nothing more than removing two nuts and washers from the cylinder head fixing and separating the pipe from the silencer.
Martyn

I seem to remember needing to remove the engine mount(s) or it makes it virtually impossible. If the manual suggests it in the ''removing the exhaust'' section it would be advisable to listen.

That said, with a LOT of ''wangling'' it may still be possible to remove it without removing the engine mount.

Jarrah

Cubber · Super Guru

TT-R250M wrote:
I seem to remember needing to remove the engine mount(s) or it makes it virtually impossible. If the manual suggests it in the ''removing the exhaust'' section it would be advisable to listen.
That said, with a LOT of ''wangling'' it may still be possible to remove it without removing the engine mount.
Jarrah

The extract you gave above, Jarrah, is from page 4-2 in the "engine removal" section of the Service Manual.

It doesn't refer solely to exhaust removal alone.

Martyn

TT-R250M · Super Guru

Cubber wrote:
TT-R250M wrote:
I seem to remember needing to remove the engine mount(s) or it makes it virtually impossible. If the manual suggests it in the ''removing the exhaust'' section it would be advisable to listen.
That said, with a LOT of ''wangling'' it may still be possible to remove it without removing the engine mount.
Jarrah
The extract you gave above, Jarrah, is from page 4-2 in the "engine removal" section of the Service Manual.
It doesn't refer solely to exhaust removal alone.
Martyn

I do realize that Martyn but my info above still stands.

The fact that they mention removing the mount before the muffler instead of in a separate section should tell you something.

Let me ask, have you removed one lately Martyn and did you find it hard to get past the engine mount??

Jarrah

Cubber · Super Guru

TT-R250M wrote:

Let me ask, have you removed one lately Martyn and did you find it hard to get past the engine mount??
Jarrah

Yes, and yes a fiddle to manoeuvre without damage to bike frame or skin. wink

But not impossible, AND without removing the head steady OR engine bolts. aww

I have done it since the question was posed, just to test my theory due to the lack of specific detailing in the Service Manual. smile

Martyn

TT-R250M · Super Guru

Cubber wrote:

I have done it since the question was posed, just to test my theory due to the lack of specific detailing in the Service Manual. smile

Martyn

Bet that was fun biggrin

At least we now know it is possible, but much more practical to remove the mount me tinks wink

Jarrah

TTRfan · Super Guru

I think that there is a slight difference in the header bends twixt one and another. Some I have struggled with in the past but I am on a roll currently and they all go on/come off with no bother.

A tip is to put some duct tape over the frame where the paint gouging usually occurs wink

Brian

TT-R250M · Super Guru

TTRfan wrote:
I think that there is a slight difference in the header bends twixt one and another.
Brian

I think I'm going to agree with Brian here as my US header pipe seems harder (if not impossible) to remove from my 1999 model without removing the mount. Contrary to this, my older header pipe seemed to remove easily enough from my 1994 OE model??

Jarrah

Cubber · Super Guru

Moving the head mount achieves nothing, believe me. confuse

All the engine mounting fixings would require loosening (or removing) to allow any movement.

My TTR engine is firmly fixed in the frame by a front head mount, rear head mount, front lower engine mount and two rear engine mounts.

Jarrah, are you telling me that by just removing the front head mount the engine or frame can be moved to enable the header's removal? confuse confuse

Have you tried it recently?

Martyn

TT-R250M · Super Guru

Cubber wrote:
Jarrah, are you telling me that by just removing the front head mount the engine or frame can be moved to enable the header's removal?
Have you tried it recently?
Martyn

LOL, no!

I am saying that the mount gets in the way.

I remember from installing it that I had to remove the mount to make it easier. Whether this was necessary or I should have just continued on swearing at it is anyone's guess. wink

Jarrah

Bugeye_bob · Veteran Member

Cubber wrote:
Moving the head mount achieves nothing, believe me.
All the engine mounting fixings would require loosening (or removing) to allow any movement.
My TTR engine is firmly fixed in the frame by a front head mount, rear head mount, front lower engine mount and two rear engine mounts.
Jarrah, are you telling me that by just removing the front head mount the engine or frame can be moved to enable the header's removal?
Have you tried it recently?
Martyn

Im 100% here still, did mine twice in the last week, polished the standard front pipe and replaced the gasket the 2nd time,
Its a 5 mins job and no mounts need to be removed.

Markvan · Guru

I must be amongst the lucky ones. My header pipe is easy to remove. I could do it blind folded. ( not really). But i may just try that next time

TTRfan · Super Guru

Following the discussions about difficulties in fitting and removing the header pipe, I thought I would have a go with one of Totally TTR's polished stainless steel shorty header pipes. I am pleased to say that it went on and came off with no hassles!

Cubber · Super Guru

Cor blimey - looking at that it seems I did mine the wrong way! confuse

I'm going to have to read the maunual again and check.

Do I have to take the tank off, the side panels, the seat, carburettor, wiring, air box, forks, front & rear wheels, mudguards and things off just to fit/remove the header? biggrin

Thanks, Brian.

Martyn

tripodtiger · Senior Member

Going to re-ignite this.

There is no way I could remove the header on mine, today, without removing the engine mount.

With it removed, it slides out very easily, with just a hint of a twist (darlings).

I tried to record what I did so I can make a bit of a video, 'ron. Don't wait up. Brexit may be achieved first, now that your Boris has a majority. What's he going to do with it, besides Brexit?

TTRfan · Super Guru

I have had a few header pipes that were silly tight and ended up scratching the frame getting them on and off. My guess is that they had been nerfed and bent slightly out of shape at sometime in their past life.

The Tories have made some big promises as can be seen in their election manifesto here. I guess they have "to get Brexit done" to see which projects they will then give priority.

Brian