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

LOL - yeah - on the beach is more like it Simon 

I have accumulated a blue tank and plastics over a period of time with a view to using them on a project such as this. Also, I like a challenge 

Also, the white plastics are getting like unobtanium so I am hoping to subsidise some of my spend by liquidising them at some point.

As you can see, I have a bit of work to do so am not chasing for the 350 kit - yet 

After taking off the tank, I found the other half of the field underneath so a bit more power washing was required!

The two top airbox bolts were well seized on and would not undo. Also, it's almost impossible to get anything on to grip the captive nuts so I ended up grinding the bolt heads off 

A least it gave good access for the final power wash and the TTR is already looking a bit more hopeful. 

The TTR is now tucked away for the night having had a thorough dowsing in WD40. It now stinks out there 

The PO has "modified" the wiring around the battery and solenoid area so that'll need re-instating but my objective tomorrow will be to see if I can master the kickstarting technique and fire her up. Before that, I guess I need to sort out a battery to replace the one that came with the bike which is absolutely dead - not surprising after being stood up for ten years  and remove and thoroughly clean the carb out.

Looking forward to it 

Another one, Brian. 

How many will this one be that you've done since starting?

Martyn

Carb re-assembled and fitted along with a good inlet stub.

I turned my attention to the airbox and thought I should check the filter. Good job I did as the foam just fell apart when I touched it. Guess I will be needing another filter then 

Just goes to show that the foam doesn't last forever - or maybe the PO used ordinary engine oil on it rather than proper filter oil 

I had an overnight brainwave. It's very rare for a TTR to lose its spark so had to be something I was doing wrong. My thoughts were correct - it turned out the lack of spark had a simple fix - change the position of the kill switch 

My excuse is that I always use the key and never the kill switch so I didn't give it a thought at first!

Anyways up, I checked and there is now a good spark. 

As I started kicking the bike over, the oil must have got up around the piston and rings as I could feel the compression improving. However, I knackered myself out without even getting a backfire.  

The kickstart started to wobble around like a wobbly thing and I caught my shin a couple of times. Doesn't that smart eh?  So, another diversion and off with the kickstart lever. The reason for the wobbliness is obvious. The retaining screw has a big groove worn into it. Plus the little ball that is supposed to hold the lever in the in or out position is refusing to come out of its groove 

Unfortunately the screw isn't listed on the parts fiche so it may be a case of filling the groove with weld and then filing it back into shape.

I recalled creating a web page showing how to fit a kickstart mechanism (see here) and at the bottom of the page is some information about the ball bearing and spring. Sadly no source was given for the screw 

Getting out the ball bearing was a bit of a 'mare! Drill bits wouldn't touch it and grinding stones ineffective. I resorted to reducing the size of the ball bearing using a little cutting disc on the Dremel and, after a bit of a struggle, I managed to get it out. The spring was also playing hard ball and got a bit stretched on its way out 

I am pretty sure that I bought the correct sized 5.5mm diameter ball bearings a few years ago to use in a kickstart but, what are the chances of me finding the spare ones? This is why there is never such a thing as a quick job when fettling bikes 

Long story short, I actually found the packet of ball bearings! I had to re-drill the hole to 5.5mm so that the new ball bearing would fit without binding. I found a shouldered bolt that was a good enough fit to hold everything together, a good dob of grease and it's back on the bike and working fine - the kickstart that is - sadly the TTR still doesn't want to start

Brian

Thanks for the vote of confidence John - most appreciated!

I have been brought to a halt as I just can't get the TTR started on the kicker - probably my technique - or lack of it 

Got a good spark, decent compression and also drained the carb and tank and refilled with ultra-fresh petrol bought from the local garage this morning but not even a cough or backfire. Really frustrating.

I want to check the engine, clutch, gearbox and electrics are all OK before tearing it apart so that any spares subsequently offered for sale can be guaranteed as tested.

I may get my brother to try tow starting it with me...........

Just spent a happy hour with my brother towing the TTR up and down the road. The engine was completely dead and it wouldn't even backfire 

I was sitting down having a cuppa and it dawned on me that I hadn't put the suppressor cap back on the spark plug after taking it off to test for a spark 

My ever-patient brother helped me bump start it. It started up almost immediately and, after a puff of smoke, ran nicely. The clutch, gears and brakes are all working fine - not bad after a 12-year lay up outdoors uncovered!

The TTR pulled nicely in all the gears so the carb must be set up perfectly for it.

I was a bit apprehensive about stopping the engine but was pleased to find that I can actually start it on the kicker now 

Having checked out the engine, gearbox, clutch and electrics, the strip down can now start.

Thanks Adam 

It's a good job I retired and Steve is doing all the important stuff these days eh? 

I am getting more of a liability as the years roll by. My grand daughter was on a visit from her home in Spain and asked Trish (Mrs TTR) what she did for a living. Trish jokingly explained that she was a full-time carer for granddad and the little girl fully believed her. I am beginning to think that Trish may have been closer to the mark than she realised 

Anyways up, I am looking forward to the morra and tearing that TTR apart 

Brian

Back on the strip down again.

Once I got the side stand off I could see why it had so much free movement in the up position! I will need a new bolt as well as a step has been worn in it which will also have contribute to the wobbliness! I will need to build up the inner edge of the sidestand (anyone old enough to remember that we used to call them kick stands back in the day?) with weld and file back to shape.

I had to cut the old chain off as I couldn't see a split link and I guess a rivet link had been used. When the chain dropped off so did the lower chain guide. I don't think that's gonna be repairable 

 I knew I could count on you Martyn 

OK - back to the project bike. It's been really fighting me and the engine mount and swing/linkage arm bolts have not really wanted to come off at all   I have had to use the half inch drive socket set, windy gun, nearly a whole can of PlusGas and, occasionally, my biggest Irish screwdriver 

I am knackered now - it feels like I would imagine after a wrestling match!

I can't get the engine out as the header pipe is stuck in and if I hit it any harder with the hide hammer I am going to put dents in it. I have drowned it in PlusGas and, if that doesn't ease it then I will attack with the blow torch.

The rear master cylinder bolts are also proving to be a PITA. I have tried using the impact driver but it started to round out the Allen heads. My possibilities are heat and or putting a cold chisel to their edges to see if I can get them to move that way. I don't think there is room to get Mole Grips on them 

I might just tidy up and call it a day and try again tomorrow when I feel fresher 

To try and take the guesswork out of which size cable clips go where on the frame, I decided to be more methodical this time. I took off 11 clips and they are four different sizes: four 6mm, one 8mm, four 15mm and two 20mm. These sizes are the approx id of the closed clips. 

I have made an assumption (possibly a dangerous one!) that the clips on the TTR I just stripped were correct but, if so, this is what I got:

I'm a Johnny-come-lately around here but, I just reckon TTR250 should have the deep purplish blue frame. It's so distinctive of the model, that's all.

Not my bike and just another opinion.

Otherwise, I like the write up so far. I reckon this one was a worse starting point than mine. I'm sure it will be fabulous when you're finished.

Came back to the Forum after a small break, and I found this thread! I really like the detail in this rebuild. Awesome work!
I'm busy looking for another OE for myself to rebuild. But these bike are very scarce in South Africa.

A further update.

After careful thought, I have decided that this project would be one too many so will instead build my 350 engine and put it into my existing trail TTR. One less bike to accommodate, maintain, tax and insure 

That means that all the parts I have accumulated for the build from the frame to the switch gear will be sold.

I will also be looking to sell my existing 325 engine based on the Thumper Racing big-bore kit.

Apologies to any project junkies watching this thread but I promise to document fully my 350 build 

Brian

Exactly my sentiments Dan. I spend too much time fettling and not enough riding! Can't remember the last time I went trail riding 

Amongst my stash will be forks, rear shock, Motad exhaust, blue plastic tank, side panels, rear mudguard, seat, etc etc. These will all be cleaned up and put up for sale in Steve's Totally TTRs shop as I get around to it.

Brian