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The RUM project
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The Resurrection of an Unloved Motorcycle has started. The bike has been entombed in my basement for years and after a quick dust-off and preliminary inspection I discovered that it's in remarkably good condition. 


For background information:

https://ttr250.activeboard.com/t65315848/new-member-from-north-carolina/

 

 

First time it's been outside since 2012

 IMG_7683e.JPG

 

Very little wear or inappropriate service

IMG_7687e.JPG

 

Front fender was changed (Polisport) at some point, the headlight bezel has tremendous UV damage

IMG_7689e.JPG

 

Tires, brake pads, chain, sprockets, and guides all look original

IMG_7690e.JPG

 

It doesn't appear to have been opened yet

IMG_7693e.JPG

 

Up next:

Wonder if the crank turns?

What's that smell coming from the carburetor?

Better make a wish list...

 

 



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HI Leonard
That looks like a neat low mileage TTR, excellent base for your project. Even the frame paint isn't rubbed much.

What are your special parts you have been accumulating?

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To look at it, it's a change fluids, fresh battery & petrol and you're gone! job.

Good luck with this one. I had almost no dramas in getting mine back on the road. Just time, dirt and money.

North Carolina. Do you remain snow free? Or are you just coming into riding season?


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In the Riverina.

'73 RD250, '76 RD400, '80 XS1100, '81 RD373LC, '96 Tiger 900/sidecar, '02 TTR250



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Kaos -

I feel like an idiot for not noticing it's potential. I literally put it away and forgot about it. As for part collecting... after my wife rejected the bike, I thought I would convert it to dual sport and ride it on the coast and do some light overlanding. The US models are not street legal but it is possible to get them registered if you jump through the right hoops. From there, I went through the thought exercise of competing in enduros, harescrambles, and generally ruining the machine. Ultimately, life got in the way and I would buy the odd bit as I thought about it. The parts pile is pointed at maintenance and DS conversion but after taking a closer look at it, I'm not so sure that makes sense anymore...



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@Kaos,

To answer your question about specific parts, I have found the following:

2 sets of new tires (Kenda K270 F/R, and Kenda K760 F/R)

Enjoy seat cover

Enjoy graphics set

brake pads F/R

520-o chain

13T & 14T front sprockets

52T rear sprocket

Polisport Halo DOT headlight with screen

Tusk DS wiring kit + relay, horn, LED T/S F/R, LED tail/brake light, etc.

2 sets of DS mirrors

OEM graphics (some from different years)

DS bars with cross member and rise

Trailtech instrument cluster and mount

Railblaza mounts

GoPro Hero5 and mounts

clamp on grips

bar risers

2 sets of hand guards

Polisport fork boots

oil filters

Castrol 4T 10w-40 oil

spark plugs (NGK CR9E)

Twin air filter  

caliper rebuild kits F/R

master cylinder rebuild kit

brake and clutch levers with perches

boxes of metric hardware

maintenance and specialty tools

Most of what I've collected and recently found has been maintenance and dual sport conversion related. It's like my birthday every time I open a box.



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Tripodtiger - 

 

I think you're right, this is more of a 'basic maintenance and minor repair' project than a resurrection. Did you happen to document your build?

 

In Eastern/Coastal NC, riding season is all year. We do have an occasional snow but it doesn't accumulate much and disappears quickly. The real problematic weather is ice storms and hurricanes. Ice storms cover everything in 1/4" or more of ice and are dangerous - fortunately they only occur once every few years. Hurricanes, well, they happen seasonally and tend to decimate whatever they land on.

 

 



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Yep, mine's recorded on 'ressurection of a scrap heap' bike. Latest (last?) purchases for that are a B&B Offroad sump guard, a 22l Acerbis tank, new gear lever and another set of fork seals.


I find the weather in some places a bit of 'wtf?'. I reckon it gets cold here and we don't get snow or sleet mostly. American & continental ice storms don't rate much press here, except for the infrequent pretty photos - to make it look nice and pleasant, if you can believe that. Hurricane, cyclones - same same really. Maybe the wind direction is different north v south. Our lows spin clockwise. And I'm far enough south not to worry about them anyway. Hey, it's pretty much forgotten how to rain here. Makes riding predictable of nothing else.

Good luck with it. I also find it interesting that US Yamaha didn't make the bike comply with road legalities. Can you make it road legal?

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'73 RD250, '76 RD400, '80 XS1100, '81 RD373LC, '96 Tiger 900/sidecar, '02 TTR250



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tripodtiger wrote:

I also find it interesting that US Yamaha didn't make the bike comply with road legalities. Can you make it road legal?


It seems that there are differences between States but I found a thread showing how it can be done here - https://ttr250.activeboard.com/t49719249/street-legal-a-tt-r-250/

Brian



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Tripodtiger - 

I did see your project and failed to connect you to it. Nice work! That thing was a mess when you started, thank you for saving it.



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Valve lash was in spec and the cam drive is very clean

IMG_7709.jpg

 

 

This may be of interest - I believe that this carburetor was OEM and never serviced before I disassembled it...

IMG_7720.jpg

 

I did not expect to find a #134 main. The US model specification is #50 pilot and #137 main. What happened here? This bike ran very poorly for the 10 minutes I let it run.

IMG_7725.jpeg

 

 



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I had the headlight assembly in my hands and intended to throw out the bezel when I accidentally scratched the heavy UV damage. By chance and curiosity, I started to scrape off the brittle skin of the bezel.

 

It looks like garbage and I removed the assembly to discard it.

IMG_7684.jpg

 

Scraping led to this..

IMG_7695.jpg

 

which led to complete part scraping...

IMG_7698.jpg

 

then sanding (400 grit)

IMG_7700.jpg

 

and then heat gun and you can see where this is heading...

IMG_7706.jpg

 

I am now experimenting with boiled linseed oil and enamel reducer to restore some luster. Maybe this will work?

 



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Meanwhile:

1. The crank does easily turn
2. The carburetor will survive despite growing a new petrol variant
3. The air filter disintegrated into foamy dust
4. Chain and sprockets are in spec
5. Swing arm and rear axle bearings are good
6. Rear rotor and brake pads are good
7. Badly needs brake fluid changed
8. Evaluation continues...

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This project started as a 'resurrection' and I thought it would end as a registered dual sport for coastal use. The more time I spend with this bike, the more I want to see what it's like in the woods and on a harescramble course. I have made a decision for the intermediate phase of this project - I will return this machine to it's original intended from, a US model trail bike. Now, I may still convert it to DS (eventually) but I want to get acquainted first.



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For the US market (and likely others) Yamaha pushed a progressive line of dirt-only trail bikes - all in a TTR family. 50cc, 90cc, 110cc, 125cc, 225cc, 230cc, and 250cc versions were available and all were blue. The idea was to introduce riders early and to promote brand loyalty (XR, KLX, DRZ series were similar). The problem was that machines like the WR250R, XT225, XT250, and the TW200 were already street legal and the TTR250 did not have the benefit of the older, more relaxed emission restrictions like the XTs. I speculate that a legal TTR250 was eliminated from consideration because it could not meet the emission restrictions at the time of US introduction (1998) and competition with the long running XT225 and TW200 was counter-productive. Despite the universal enthusiasm for a small bore dual sport, these bikes languish on showroom floors for years sometimes in the US. The prevailing trend in this market is that bigger is better and every 16 year old child with a learner's permit needs no less than 1000cc for their very first motorcycle.

It's true that each state mandates if and how a machine like the TTR250 can be made legal. Some states are relatively easy to deal with while others are strictly prohibitive. In the case of North Carolina, the simple option is to document the DS conversion and claim that the machine is self-built to register it as new. If accepted, the 1998-2006 Yamaha TTR250 would then be titled and registered as a 2019 Fat Leopard Special.



-- Edited by Fat Leopard on Wednesday 17th of April 2019 04:39:41 PM

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I used some Plasti-Dip on the rear guard. Worked ok considering all I did before hand was to clean years of dirt etc off and a very superficial sanding to remove the shine.

TTRs were popular amongst the enduro riders over here. Especially the older lot that didn't need to win any longer. Ballards even went from XR to TTR as the cornerstone of their business.


2019 Fat Leopard. That would get the attention of the coppers when their image scanner sees the rego plate. Fingers crossed they are in a good humour at the time.



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'73 RD250, '76 RD400, '80 XS1100, '81 RD373LC, '96 Tiger 900/sidecar, '02 TTR250



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US and NC registration laws are silly. You could own a bike for 20 years and it could have only one or possibly several unique registration numbers over that interval - all random and disassociated from the year of manufacture. I still haven’t decided what to do with the ‘19 Fat-pard but I did just ride it this evening.

*** IT LIVES ***

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*** IT LIVES *** 

 

Good news smilesmilesmile



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Some tire and wheel work - I discovered the rear axle was installed backward in the process.

IMG_0078.JPEG

 

 

Everything in the rear checks out. Close up of some of the new graphics - I had more trouble than expected installing these.

IMG_0079.JPEG

 

No issues in the front end either. 

IMG_0083.JPEG

 

I can see the light at the end of the tunnel now.



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Reconfigured controls

 

IMG_0080.JPEG

 

IMG_0087.JPEG



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Still several details to sort out but this one is ready to ride some.

 

IMG_0084.JPEG

 

IMG_0085.JPEG



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I have a Polisport Halo headlight to install if I convert to DS but I like the OEM headlight for now. Where can I get a replacement bulb? They seem to be gone in the US.



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In the meantime, my wife has been eyeing the new build with interest. She unexpectedly bought herself MX pants and helmet recently. Maybe she ends up with it after all?



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Another side view:

 

IMG_0086.JPEG

 

I don't think I like the blue seat cover with this graphic set, maybe a black one would be better? It's almost a shame to change it since the original is in near perfect condition.

 



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Wow those plastics are shiny!
Looking really good. Well done.

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I noticed the shiny too. Looks good.

If your wife takes it, I'd assume that means you've got permission for another bike.

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'73 RD250, '76 RD400, '80 XS1100, '81 RD373LC, '96 Tiger 900/sidecar, '02 TTR250



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Looking great!

How did you get on with the tank decals? My Enjoy Mfg ones have always needed trimming to fit properly.

Also the RH side panel has a tricky curvature such that I always let a mate, with more experience than me, fit that one.  He uses hot water from a kettle rather than a hot air gun which is what I use.

Regarding the seat, I think Enjoy do a cover with blues sides and a black top panel which would look really good wink

Brian

image002.jpg



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Tripodtiger,

I laughed at your response. I'm fortunate to have a wife that tolerates and supports my hobbies and she would be in favor of me getting anything I want. I'm also old enough to know better than to fill the basement with 37 project bikes. If she does choose the TTR250 then I will immediately acquire a WR. In the meantime, she has a standing offer for me to buy her any bike she chooses - at the moment it's a TTR125LE.



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Brian,

I want to thank you for your substantial content contribution to this community. I scoured your posts relative to graphics and found a ton of useful information. Honestly, I had difficulty with the Enjoy kit installation and lost patience more than once. The right side panel was the second bit I attempted which resulted in some creative trimming - don't look too closely. I did not follow your pre-trim approach on the tank set in favor of trimming to suit after application. All I can say is that it "worked" - stop peeking. I did use a method that may be of interest otherwise:  I cut a narrow strip out of the backing paper to expose a little adhesive then placed the decal firmly but with less commitment. That allowed me to back-peel a section at a time controlling the sticky monster.

I have a black gripper seat cover that I think will look good. I stopped using OEM vinyl covers for any serious dirt riding because it gets too slippery. Since I ride like an escaped felon at every opportunity, gripper seat it is.



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My brother in law is an upholster he covered my seat with marine gripper material it stretches in all directions and fitted over the original cover 

Comfy and super grippy love it 



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Ttboof,

That settles it then - I will recover the OEM seat in gripper skin .

 

Brian,

Your builds have inspired me to keep the TTR instead of dumping it years ago. I love the look of this one:

image002.jpg

I do like the blue/black seat cover.

 

 



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I found 5mm spacers from McMaster-Carr that fit well for anyone in the US that may want a slight bar raise.

https://www.mcmaster.com/94669a372

 

IMG_0088.JPEG



-- Edited by Fat Leopard on Wednesday 8th of May 2019 06:16:57 PM

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Night riding now possible. 

 

IMG_0104.JPEG

 

IMG_0105.JPEG

 

I think that a modern headlight exchange is in the near future and possibly auxiliary driving lights. Underwhelmed by the stock headlight.



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Finally ready to go ride with my wife. I think RUM Project is complete.

IMG_0143.jpeg

 



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Great job! I hope the ride goes well wink



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Finally back on here to see the end result. Good one!


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'73 RD250, '76 RD400, '80 XS1100, '81 RD373LC, '96 Tiger 900/sidecar, '02 TTR250

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