TTR125 Thread

[ballistic_ken]

I have a '05 TTR 125 and the clutch engagement is way out, no engagement at all until the clutch is almost fully released.

I am assuming the clutch pack is due for replacement, but am open to other ideas.

[JWhitmore44]

Originally Posted by ballistic_ken

I have a '05 TTR 125 and the clutch engagement is way out, no engagement at all until the clutch is almost fully released.

I am assuming the clutch pack is due for replacement, but am open to other ideas.

I know the lever on the clutch actuator is a bit short, but that usually causes a stiff clutch pull. I have heard (think it was thumper talk) of folks extending the that little lever. It may make the throw a littler longer but it sound more like you have a worn clutch. I assume you are getting close the the end of adjustment? it's not a stretched cable is it?

[truck6driver]

Hey folks,

I bought an 08' for my son a week ago. It had what I thought was rocker arm noise that ended up being piston slap. So I pulled the top end and found a galded piston, well crap. The kicker is I accidently dropped the cam gear washer behind the flywheel. I pulled the side cover but could not see the washer. Using a puller I attemped to pulle the flywheel off. the puller ended up bending the threads of the crankshaft. Now I have an engine that needs a piston and a crankshaft.

Is the crankshaft really that soft? Has this happened to anyone else.

No aftermarket crankshafts and a new OEM one is $300


Any help would be appriceated.

Ray

[Cpt. Ron]

Originally Posted by truck6driver

Hey folks,

I bought an 08' for my son a week ago. It had what I thought was rocker arm noise that ended up being piston slap. So I pulled the top end and found a galded piston, well crap. The kicker is I accidently dropped the cam gear washer behind the flywheel. I pulled the side cover but could not see the washer. Using a puller I attemped to pulle the flywheel off. the puller ended up bending the threads of the crankshaft. Now I have an engine that needs a piston and a crankshaft.

Is the crankshaft really that soft? Has this happened to anyone else.

No aftermarket crankshafts and a new OEM one is $300


Any help would be appriceated.

Ray

Sounds familiar.....

Yes, the crank is that soft. When I did it to my son's bike, I ground down the end of the crank shaft so the flywheel would slide back on easily without screwing up the tapered finish of the flywheel. I then machined down the left side of the inner hub of the flywheel so that the thread of the bolt would engage again. I believe I ended up removing something like 1/4" of steel. Bolted it back up and off we went.