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Thread: TTR635 Project

  1. #1
    Registered User ls400x's Avatar
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    TTR635 Project

    Rescued this little fella from gumtree for a bit of a project. It's a 1999 Yamaha TTR600 Belgrada, Italian manufactured with 46mm Paoli fork, Ohlins shock and Brembo brakes . It wouldn't start for the previous owner so I picked it up for next to nothing. It came with new tyres, Pro Taper bars, barkbusters, single seat mod plate and recent chain and sprockets. I got it home and bumped it over compression by hand and heard a pushhhhhttt from between the carb and the cylinder head. Both inlet manifolds had broken away from the aluminium.

    I've always liked this series of engine but never owned one before. Plan is for a general tidy up, Wiseco 635cc piston, basic porting, 3 angle valve job and squish clearance set.



    Everything has a stained on layer of red dirt









    Broken inlet manifolds



    A quick peek inside looks better than I expected, not burnt on sludge

    Last edited by ls400x; 07-05-13 at 12:49 PM.

  2. #2
    Registered User Gats's Avatar
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    Looks pretty decent apart from the inlet manifolds.

  3. #3
    Registered User ls400x's Avatar
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    First job: Carb

    Yamaha Dual Intake System (YDIS) setup. Photos also for reference in case I need to look at them to put it back together...





    Broken diaphram








  4. #4
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    always wondered what these are like compared to an xr600. good project
    get lead like a leader

  5. #5
    Registered User ls400x's Avatar
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    Thanks

  6. #6
    Registered User 50RTD's Avatar
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    Awesomes! Italian manufacture?

    You gonna fit a towbar? :P Should have some pull when finished

  7. #7
    Registered User ls400x's Avatar
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    Yep, Euro Yammie

    Ordered a few parts. Surprisingly Amazon.com was the cheapest for the piston kit at $140ish.

  8. #8
    aka SpaZdA (tm) mondo2000's Avatar
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    These were teh shit back in the day, when plastic fork protectors were used on RWU forks

    Nice bike.

  9. #9
    Registered User ls400x's Avatar
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    Thanks mate

    Carbs complete




  10. #10
    Registered User Instigator's Avatar
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    Motard that shit son!


  11. #11
    Registered User ls400x's Avatar
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    Hmm that looks pretty tidy, but I alread have a motard TE.

  12. #12
    Registered User ls400x's Avatar
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  13. #13
    Registered User 9triton's Avatar
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    wow -no messing about !

    i allways worry when i pull them apart -takes years to get back together

  14. #14
    Registered User 50RTD's Avatar
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    I recon he'll have it back together by the next post!

  15. #15
    Non Compos Mentos Gammaboy's Avatar
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    Last edited by Gammaboy; 20-06-13 at 08:38 PM.

  16. #16
    Registered User ls400x's Avatar
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    Yeah things got a bit out of hand today, I didn't really intend to go that far...

    Gammaboy- correct

    It is 0.5mm oversize with a genuine Yamaha piston. The piston would have probably measured up ok, the rings wouldn't have. I was worried it was going to turn out to be a chrome bore model and I would have to sleeve it, luckily iron. New 98mm piston is advertised as 10:1 comp ratio up from 8.5 or so standard.

    The cam, plain bearings, rockers and cam chain sliders look to be in great condition. The crank feels good so I don't think I'll split the cases.

    After a fair bit of research boats.net come out the cheapest for OEM parts at about 1/3 of the quotes I got in Oz.

    Ohlins got back to me about the oil and nitrogen pressure for the shock so I hope to have a crack at servicing that soon.

    Found parts fisch here: http://www.megazip.ru/ru/bike/yamaha...7/16167/200157
    Found Factory service manual here: http://service.tanga-moteurs.ro/

  17. #17
    Registered User ls400x's Avatar
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  18. #18
    Non Compos Mentos Gammaboy's Avatar
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    Last edited by Gammaboy; 20-06-13 at 08:45 PM.
    "Where can we get hold of a Vincent Black Shadow?" "Whats that?" "A fantastic bike," I said. "The new model is something like two thousand cubic inches, developing two hundred brake-horsepower at four thousand revolutions per minute on a magnesium frame with two styrofoam seats and a total curb weight of exactly two hundred pounds."

  19. #19
    Registered User ls400x's Avatar
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    Quote Originally Posted by Gammaboy View Post
    Would be interested to hear the oil/pressure spec, I've got an old ohlins I need to put a longer reservoir hose on...
    10w and 140psi

  20. #20
    Non Compos Mentos Gammaboy's Avatar
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    Last edited by Gammaboy; 20-06-13 at 08:45 PM.
    "Where can we get hold of a Vincent Black Shadow?" "Whats that?" "A fantastic bike," I said. "The new model is something like two thousand cubic inches, developing two hundred brake-horsepower at four thousand revolutions per minute on a magnesium frame with two styrofoam seats and a total curb weight of exactly two hundred pounds."

  21. #21
    Registered User ls400x's Avatar
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    A schrader valve if that's what you mean by needle valve?

  22. #22
    Non Compos Mentos Gammaboy's Avatar
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    Last edited by Gammaboy; 20-06-13 at 08:45 PM.
    "Where can we get hold of a Vincent Black Shadow?" "Whats that?" "A fantastic bike," I said. "The new model is something like two thousand cubic inches, developing two hundred brake-horsepower at four thousand revolutions per minute on a magnesium frame with two styrofoam seats and a total curb weight of exactly two hundred pounds."

  23. #23
    Registered User ls400x's Avatar
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    Nek day:










  24. #24
    Registered User ls400x's Avatar
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    Quote Originally Posted by Gammaboy View Post
    Cheers, they're a needle type inflator aren't they?
    14bar, I remembered incorrectly.

  25. #25
    Registered User 50RTD's Avatar
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    Porting is bulk sexytimes!

  26. #26
    Registered User ls400x's Avatar
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    Parts starting to come in. Forged 98mm piston.


  27. #27
    Registered User 9triton's Avatar
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    ^^^^its up side down - send it back

  28. #28
    Registered User Mini_Me's Avatar
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    This bike is v cool! Nice project

  29. #29
    Registered User ls400x's Avatar
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    I started on the forks but struck a few problems. Seals are the wrong size, bushes worn, base valve wont come out of one fork leg without a special tool. The leg that the base valve won't come out of is barely compressable, I have no idea what could cause that, it's like someone has put a massive spacer on the spring to preload it.

    Base valve disassembled for cleaning.


    Full break down, pretty simple.



  30. #30
    Registered User ls400x's Avatar
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    I got bored while I was waiting for parts and this happened:







    Then the parts turned up, mostly bearings and seals for wheels/linkages/swingarm/shock



    Not sure what to do with the forks yet, bushes need doing and it's worth about $400 in parts. Thinking of doing a mx USD fork conversion.
    Last edited by ls400x; 15-06-13 at 08:34 PM.

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