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

Good luck, Steve.

Does iot have a saddle? 

Oh by the way - stardom congratulations to you and Lisa. Mrs Cubber and I saw you both on a house programme on TV the other night. No mention of TTRs though.

Martyn

Frame now with ICS powder coaters in Cullompton, now I need to get on cleaning everything and doing a top end rebuild

I had some much needed help today, the Guru came to visit 

I had pre- ordered the steak pasties, just to keep his energy levels up!

So we set about the engine.....

Always handy to have printed of the torque sequence!

We stripped all the parts off and found that the piston and barrel had been scoured

Once they were removed we found that there was heat marks and scouring to the little end of the conrod

Brian then tested the big end for play and we found that there was play meaning the crankshaft would have to be sent for repair This is a very unhappy engine As luck would have it there was a whole crankshaft with conrod in excellent used condition in the stores and I decided to take it out of the shop and fit it to this bike, saving time for the crankshaft to be sent away for repair.

Next up we started to split the casing's to replace the crankshaft and found that the oil pump did not look so great, will be replacing this.

Lot's of wear marks.

Now as for the clutch, think it has seen better day's

Now I knew that the engine needed a top end rebuild when I bought the bike, but did not realise I would be fishing around in the bottom end and in a funny way I am quite glad that I am having to do this, as I want to learn all from Brian that I can and we really are doing a full rebuild here.

Now when the casing's were split all the rest of the bearing's and gearing's have been fully checked and are fine (phew).

Kept the cam buckets and valves in a nice box, so would not lose there order in the cylinder head.

Brian and I then got on with getting some parts back together, before we both run out of time, was 10am when we started and 6pm when we finished.

I will be putting all the parts of the engine back together over the next couple of day's, new barrel and piston will be fitted, really learning everything on this build as it is my first I will be doing everything thoroughly.

Thanks to Bri for all he's help today

Steve

BM Steve wrote:

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ttr steve wrote:

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A wise man said to me once, a bike in bits will take up more room than a bike that is not and here is the proof

Steve

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 Kind of true But I have nearly my whole DRZ400 stored in a 4 draw filing cabinet and ontop of it

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 I hope its stored in files in alphabetical order. 

Got the engine all back together now, after a serious amount of work!

Parts replaced inside the engine

Clutch plates

Pressure plate

Oil Pump

Crankshaft

Piston and barrel

Valves lapped

Sprag and Idler gear checked, Have I missed anything? Oh yeah cam chain

Putting the valve collets in was so easy with my new tool

Just put everything in and push down!

After all that work, a nice spray job for a like new engine

Note the top of oil cap, to protect where the starter should be

Oh and I checked clearances and re shimmed as necessary.

Liked the tool so much I am now stocking them

 http://totallyttrs.com/epages/699105d9-e4cc-4b32-b236-84e72cd67f84.sf/en_GB/?ObjectPath=/Shops/699105d9-e4cc-4b32-b236-84e72cd67f84/Products/TTR-0672

Brilliant bit of work, Steve.

You and Brian make it all look so easy and straightforward, thanks for all the pictures and information.

Martyn

Finally got to start putting the bike back together this morning!

Started of like this at 8am

Moved onto this

After I had replaced all the

Swing arm bearings

Linkage bearing's

 Top shock bearing with the one of the kits that I sell https://totallyttrs.com/epages/699105d9-e4cc-4b32-b236-84e72cd67f84.sf/en_GB/?ObjectID=1718485

Then Brian turned up to land a hand and give me some moral support and drink tea! No pasties as we are both on a new year / new health kick

I have replaced all the wheel bearings

Checked and re- greased the steering bearings

Fitted new brake pads front and back

Fitted new grips and Handguards

Finished work at 10pm and now looks like this! Yes I know my tools are messy, will tidy up first thing in the morning

Yes this bike will be for sale, when finished and I am off to do some more now.  Fitting all new plastics Kit 

Will be like a brand new bike, but better, as it will have a motad fitted with the shorter header pipe and the lovely wide stainless steel foot pegs that we do https://totallyttrs.com/epages/699105d9-e4cc-4b32-b236-84e72cd67f84.sf/en_GB/?ObjectID=1718295

Steve

Not done to much today

Got the electrics all working, to find out the  aftermarket headlight I thought I would try, turns out to be rubbish.

Back to polisport me thinks!

All the rest is working perfectly

Hi Steve

Mt43 front and back.

Would think the new owner will want to add their own rubber, so just put on what I had.

Though most people around here run mt43 on the back and mich comp 4 front.

Cheers Rich

Nice to see you today

Got the new headlight today and number plate. Of out on MY bike tomorrow, so wont be doing any more until Sunday.

Motad and Shorty header pipe to fit next, just to give that bit of extra punch This bike is having all the bells and whistles fitted

Some lucky person will be getting one of the/ THE best TTR's out there

Looking forward to running the bike in, even though I will have to go around the lanes and not ride them No way I am going to scratch it!

Fitted the decent Polisport headlight tonight, much better

Next up the motad and Shorty header pipe, just to give this little bike a bit more punch

Then another new plastic fitted.

And I have finished for tonight.

Frame guards fitted, tail tidy fitted back end is looking very nice

At last, she has made it out of the garage!

Took her to treens for an MOT  http://www.treenmotors.co.uk/

 A proper bike shop run by people with engine oil in their veins

One advisory Brake pedal pivot bolt worn, will replace!

The bike ran so so sweet, no rattles bangs crunches or mishaps. Nice and smooth up and down the gears Really looking forward to running this bike in, is a real treat.

This will be the ultimate TTR for some lucky person, not only have I fully rebuilt the engine ( with new piston and rings) and powder coated the frame, it has had all new plastics and all the extras someone could want.

Bashplate

wide footpegs

motad

shorty header

tail tidy

case saver

frame guards

gripper seat cover

complete bearing replacement (apart from steering ones, they were checked and re-greased)

If anyone is interested on this forum please let me know, otherwise it will be advertised on the Devon TRF forum, the National TRF forum and the dreaded flea bay! Very soon.

Steve

Hi Dan

Was writing the report while you posted!

Forgot to say, new tank graphics will be added

pug wrote:

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Will you be crossing Mr Treens palm with silver for that ticket If so when you are in there ask Clive about his TTr Raid he is about to put it up for sale an it's a runner well maintained just a bit cosmetically challenged don't offer him more than £800 for it as I could have had it off him for that.

Martyn

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He has an OE and seems interested keeping it, now I told him about the 350 kit 

pug wrote:

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Life is full of hard choices .....................................

Martyn

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I totally agree with you on your ultimate statement, Martyn.

My choice this cold, chilly morning was "Should I get out of my nice, warm bed?"

Brilliant report on the rebuild, Steve, complete with coloured pictures.

A labour of love and looks better than a new one., but don't get it mucky on a trial run.

Martyn

honda15i wrote:

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seems like a great tool for lapping the valves. How this tool is called? I want it.

 

 Oscillating valve lapper  can be found on eBay 

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