Rescuing a ttr225

I will know next time. All I had was a pair of safety glasses.

Can you do me a favor ? I need a picture of your coil pack. How it is set up. I have a ground wire that I thought was supposed to attach to it but it's smoking when I attempt to start it and I need help figuring out where it goes.

Oh gee, sorry, my ttr225 is in my moms garage in Alaska. Would the ttr125 be similar? I have that in my garage here.

Should be an orange wire to the tab. And then a ground nearby on a screw or bolt

No updates? How’s the electrical issue working out?

No updates? Hope all is well.

Sorry , life gets in the way a lot I had a bunch of progress pics and my old phone just turned black one day with a full battery so I had to drop coin for a new one. I rebuilt that old carb but it still wasn’t right. The float continued to get stuck open and gas was pouring out of it. I didn’t want to spend 300 for a real deal mikuni carb. So I got a cheap eBay replacement. Presumably from China. But it worked just fine. I still need to order a clutch cable and had planned on doing so but my car crapped out on me so I have had to pull the motor and order parts. It’s been one thing after another. I did get to load it down and take it a few miles down some field roads and through some woods to a little waterfall in a creek nearby and do some fishing. There is a pinched wire that goes to the starter that I need to fix and I put a new intake manifold on it only to find out I needed a new head gasket as well. But then all the car stuff happened. So the dirt bike has been put on the backburner, but my sons mini bike got moved to the front of the list as we wait for parts.

So we removed the old predator motor and I got him a brand new one since they were on sale at harbor freight. And I figured while we were at it we could update his paint job. There’s a shot with the old paint and headlight. Before clear coat. Well for some reason the after pic loaded to the top. The headlight is an old one I had for my sportster that the projectors loosened up in and began rattling around. So I removed the lense and screwed the projectors back into place, just to see if I could. But I didn’t know how to seal it again so I just stuck it on his bike. Now we wait on brakes. And my buddy to finish remodeling his shop.

Sweet update. Thanks! Yes, life does that... tries to get in the way of fun...

This seat is pretty pitiful, one of the nuts in the seat is stripped and the other has a bolt snapped off in it. So I think I am gonna take this apart and see if I can fix it. I was having to have it attached to the bike with a bungee net and that barely did the job. It’s cold and dark , there’s nothing else to do so it’s time to tear into this seat.
Someone on here made a recommendation about a new material to cover the seat with but blue and black were on back order last time I checked, plus the local hobby lobby has blue vinyl for about fifteen dollars a yard , and with a %40 off coupon I can get it for even cheaper. This part of the process stinks . Pulling all the staples out to try and keep the current cover intact as much as possible to use as a template. There are some dry rotted spots you can see the hole there. The cracking is pretty extensive in that area and I may just knock it all out. Removing the padding from the pan wasn’t too hard the glue is old and was only really stuck in a couple of spots I’m gonna get as much off as I can. About forty minutes and a couple of sore thumbs later and I have this pile of old glue and a little foam.

I knocked out the rest that was rotted and attempted to punch out the nut and bolt that were snapped off in the pan. But there were minor stress cracks beginning to show up in the plastic around it so I opted to just burn them out and leave some gaping holes instead. Seams counterproductive , but there is a method to my madness. As you can see one side is a little larger than the other but this won’t matter in a minute. I have an idea. From the factory they put threaded metal holes molded into the plastic. But as I said one was stripped and the other was replaced somewhere along the way with a nut. I am gonna do the opposite. I’m gonna put the bolt in the pan it will be much easier to line them up with the holes in the frame. Also easier the get them to set without my fixer material getting into the hole and causing problems. I’m gonna be using this amazing stuff to fix the pan. All you do is drop some of these granules into some boiling water and they turn clear. Then it becomes very mailable and moldable. Plus it’s reusable. And it gets super hard. I used some of this to fix the seat pan on my sons mini bike and it worked great. So here goes nothing. They look like this at first.

Then it turns clear and I use a wooden spatula to mash it all together while still in the water. It stays mailable for quite some time. So now I prep the area while this cools just a bit. I filed a few of the rougher edges but not too much the rougher it is the more weird little spots it has to hold onto. And I have a couple of ways of holding it in place I start some pilot holes with this screw, then I use a larger diameter drill bit to create some larger holes all around the outside edge of the hole I am filling. This isn’t very pretty but it’s extremely functional and since a seat or pan for one of these is hard to come by this is my best solution. My little helper always trying to get in on the action. He cracks me up. He always says “I Help” then just finds a hole to stick a tool in. Lol

When it cools down it turns white and gets super hard . I just made this piece solid. It’s normally hollow but ..... not anymore. I smashed the insta morph through the holes I drilled and pressed both sides together and it formed little tabs to help hold the new plastic in place. I placed the bulk of the material on the side that the foam would be glued back to. You would be able to see it or tell it’s there for the most part. I heated up my soldering iron and went back around the edges and melted the plastic on the seat pan and the new plastic together. This has held up really well on my sons mini bike. I have been riding my younger one around the yard on it and it is holding just fine. So I don’t see why it won’t work here. Now I just need to get some headliner adhesive from the auto parts store. Then I can glue the foam back to the pan and recover it with the new vinyl material.

More to come.....