Hi all I have a 1995 TTR250 with what looks like an exhaust from a 1994 and the bolt that holds the exhaust to the frame has gone missing because the thread is worn out, is this easy to repair by welding a nut in its place or could I tap a new thread in if there's enough meat? also can anyone identify this exhaust because I'm having trouble with the bike running too rich the carby needle clip is at number 1 (the highest it can go) to lean the mixture but its still running to rich so it could be the 142 main jet and this exhaust causing my bogging problems but the carby is a no name copy from ebay but its almost an exact copy of the original part for part, I'm waiting on a check seat valve to finish rebuilding my original carby that has a 137 main jet and both the copy and original have a 50 pilot jet
There is an ID on the exhaust YAM TT-R 250 94 3750
The exhaust should be easily repairable by welding on a nut - that part looks like stainless steel. (The main silencer body looks like aluminium?)
The carb issue is almost certainly down to different tolerances in manufacture - the cheap Chinese copies look remarkably similar, but given the fine differences in internal hole sizes you can't just assume they are the same - you have to treat it like a totally different unit and start jetting from scratch. Unfortunately, I think the ttr carb is the biggest achilles heel in restoring old bikes because of it's rarity.
I didn't know the internal holes would be different thanks for telling me I'll post back the results after installing the original carby this will help anyone when considering the copy as an option, I got the check seat valve today so I'm putting it back together and all up I have spent about $190 to rebuild it which is a lot cheaper than buying an original carby for $700 even then it could need rebuilding
