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Post Info TOPIC: The 100k km TTR Rebuild
v8r


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The 100k km TTR Rebuild
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So, ive picked up a blown up 2001 TTR250 from forum member scott and its a perfect candidate for a rebuild and to replace my troublesome 94 model. This wont be a quick build up as the usual family / work and financial pressures get in the way, more so it will be a bit spasmodic.

Plans at this stage include:

renewing all bearings in the frame (wheels, headset, linkage / swingarm)

service / renew / upgrade footpegs (undecided right now)

check and true wheels as required

setup handlebars for my height

renew grips, throttle tube, cables (throttle / clutch)

touch up frame paint as required (its in damn good nick for the age!)

touch up plastics and stickers

and the big ticket item,

engine rebuild - 270 or 325 kit, undecided at this stage

 

<pics disappeared from hosting.. hmmmph!>



-- Edited by v8r on Tuesday 9th of December 2014 08:31:31 AM

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Good luck, Joel.

You've given yourself a challenge now.

I think Scott may be a tad jealous with the final outcome, time will tell. confuse

I'm looking forward to your reports and pictures. biggrin

Martyn

 



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Budleigh Salterton. Devon



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Good luck with the rebuild V8R.

Wonder what the highest km TTR is on this forum? This one would have to be up there wouldn't it?

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Resident AG200 idiot! :)



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Yes, very jealous ;)

BTW, the rear wheel bearing was done on the last service (about 500km ago). Also the cylinder (and every other opening/wire I could find) was taped up hastily over the layers of road grime, so if you don't want the winter dew getting in there you might want to do something with that ;)


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v8r


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so, today was the day i finally got around to trucking Big K home from my bros place, after having to clear room in 3 sheds to be able to work on her. ive commenced by dropping the engine out of the frame (lol, that took over an hr, never acrtually pulled a ttr one out b4 :) ), in preparation for a wash and tub tomorrow. while scott has done a sweet job looking after her (you wouldnt think the frame is just under 100k old!), the road grime does build up over the years, so a power wash and scrub it will be tomorrow and a check over of the engine to figure a plan of attack.
Pics as requested..

 20140802_172819.jpg

20140802_164819.jpg



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v8r


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stripped down some more and scrubbed, pressure washed, degreased.. pity about my phone cam pic!

 

20140811_122716.jpg



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It certainly scrubbed up well!



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Exeter, Devon, UK

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Nice work. This bike will come up nice...

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Certainly doesn't look like a 100K machine

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Cheers William '94 TTR250 Raid Jap import '05 R1150 GSA



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Time to start looking around for a lower Km speedo



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v8r


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i 'may' have one on my sons blue ttr (18k, lived on the coast, looks more like a 100k old bike!).. we'll see ;)

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v8r


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so, a few more pics..

bore piston and general engine shot.. 

 

20140816_155217.jpg

20140816_155625.jpg

the friggen sprocket nut had me screwed for a while.. jammed up the sprocket with all manner of thing and hit it with a rattle run multiple times.. eventually it took me to fit the engine back to the frame, thread up the chain and jam the back wheel with a 1/2inch extension thru a rear sprocket hole and the frame. that plus a 6ft breaker and a decent amount of my 120kg, and the nut cracked.. wooah, thats the tightest one ive come acrosss yet!

20141209_182219_3.jpg

the clutch side is empty so, shes ready to split!



-- Edited by v8r on Tuesday 9th of December 2014 08:11:33 AM

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