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The TTR250 FAQ web pages -> TTR250 -> Repairs and maintenance -> 2006 ttr250 complete engine rebuild
Post Info TOPIC: 2006 ttr250 complete engine rebuild
little_wing


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2006 ttr250 complete engine rebuild
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hey all,

so i have a 2006 ttr250. I live in ontario canada. so 2006 was the last year for the 250 in this part of the world.

this bike was the first dirt bike that i rode and started my love for offroad riding.

the bike has an estimate of 500-600 hours the motor has never been opened. other then to check the valves way back when it was new.

the motor has alot of noise and there is some good chunks of metal in the oil filter.

i have pulled it apart and i need the following

new starter

new starter clutch

piston and rings

rebuild the head

big end bearing on the connecting rod is crap so the cases will need to be spilt.
I am thinking about sending the frame to be sand blasted and recoated

i have already rebuilt the forks and the shock

 

my question is are all the parts needed to do a complete top and bottom end rebuild still available?

i would prefer aftermarket as Yamaha wants nutty prices here in Canada for certain items

does any one have good links to aftermarket parts that i need to do the rebuild?



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TTRfan


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Hi Alex

It sounds as though you have a job on your hands!

There are loads of rebuild threads etc on here plus links to pictorial guides - this is an example.

All parts for a complete rebuild are available although I doubt you would find an aftermarket conrod kit. I am using a rebuilt crankshaft in my 350 build which was rebuilt using one of Steve's Totally TTRs conrod kits - see here - a special order item. 

Aftermarket starters are available but I think most are made in China and, sadly, the pinion teeth soon give up. That was my experience and so I now use only genuine TTR starters - or rebuild a TTR one with an armature and good pinion from another Yamaha starter. There are several good threads on the forum giving the options available. 

Similarly, owners haven't had much luck with after-market sprag clutches and my advice would be to buy the genuine part.

After-market Wiseco and Wossner piston sets are available in all the oversizes.

For the head, definitely fit new valve stem oil seals. Aftermarket valve springs are available. If the valves or the valve seats are pitted, beyond grinding in, then you will need to find a machine shop to recut the seats and regrind the valves. New OEM valves are available if you prefer.

I hope that helps. It's a shame you haven't got a Totally TTRs in Canada!

Brian



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mossproof


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I think virtually all the parts are available from Yamaha. Aftermarket pistons from Wossner, Wiseco etc are available and non Yam, but good quality, bearings are also available for most of the bottom end (there's a post somewhere detailing all the bearings required and their numbers) Unfortunately noone has come up with a good quality aftermarket sprag clutch, and the gear boss that it runs on will also be fubar on your bike if it jammed. Conrod kit is also genuine only as far as I know.

Found the link to the bearings - in Brian's 350 build thread:

ttr250.activeboard.com/t66290260/brians-350-build/

All the seals will be available aftermarket too - just google the numbers or take the list to your nearest engineering supplies bloke.

Should keep you occupied for the winter!

 

Seems like Brian was typing at the same time as me!



-- Edited by mossproof on Saturday 24th of October 2020 10:09:51 PM

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ttr steve


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Fubar!

Love that saying.

bri and Simon are giving top advice as usual



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