03 vs 06 YZ250

Lightning78
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10/15/2014 9:09am
I know I laughed my ass off when I saw that… I'll bet 90% of people looking to buy it wouldn't even notice either which is sad.
FGR01
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Fantasy
10/15/2014 10:36pm
loftyair wrote:
Just make sure the fork and shock are 06 or newer no matter what the vin says. Lots of 05 saying 06 to sucker someone. Or...
Just make sure the fork and shock are 06 or newer no matter what the vin says. Lots of 05 saying 06 to sucker someone. Or even 06 or newer with the older crap on it.
HAHA totally Lofty, you mean like this ad??? Dude has the 46 or 48mm openchamber KYB's off an older yz on there and its painfully obvious...
HAHA totally Lofty, you mean like this ad??? Dude has the 46 or 48mm openchamber KYB's off an older yz on there and its painfully obvious, I feel sorry for the poor bastard that actually buys this thinking he's got SSS forks on his bike

http://orangecounty.craigslist.org/mcy/4656315625.html







"Like New".... "Barely Ridden".... SMDH. Meth is a hell of a drug.
YamiRy239
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10/16/2014 6:48pm
Deetsmx wrote:
Lightning, you'll need the triple clamps off a newer bike to fit the sss with the steering stem from old one pressed in (forgot which, but...
Lightning, you'll need the triple clamps off a newer bike to fit the sss with the steering stem from old one pressed in (forgot which, but one is longer). You'll also need to get a newer front brake caliper (cheap on eBay). I also bought new wheel spacers and front axle but I don't remember if it ended up being necessary.
Thanks Deets.....so would clamps off of an 04 not work? The 04 had 48mm forks on it, same size as the SSS plus the steering stops...
Thanks Deets.....so would clamps off of an 04 not work? The 04 had 48mm forks on it, same size as the SSS plus the steering stops would work with the steel frame.

Did you have to do any modification to the steering stops with the newer clamps? I seem to have read that a lot in the research I've done.

Also, from what I understand, the steering stem off of the 450 is the (longer) correct length and will work with the YZ250 steel frame. Plus the 250f forks I read are shorter too and the 450 forks are the correct length, did you put 250f or 450f forks on yours?
I just did the SSS swap on my '03 a couple months ago.

The '04 clamps are a direct bolt on and you are correct that the steering stops are in the right location.

I used the clamps off of an '09 250f and swapped the stem from my '03 clamps. The steering stops do contact the stop on the frame, but in a hard crash I'm sure they will push past it. The 450f clamps do have the longer stem and are a direct bolt on. You can also use the '10-'13 450f clamps which have a 22mm offset vs the 25mm on the 2 stroke. The top clamp has to be bored 2mm to fit the older SSS forks though.

You can use the '03 caliper you just need the caliper bracket from the newer model to bolt it to the forks.

You do have to use the newer axle and spacers do to the '03 axle being longer.

The forks from a 450f are the same length as the '03, but I used the 250f forks and I can't notice the difference in length.

Hope that helps
machine
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10/16/2014 6:50pm
I have ridden both models, and I would go with the 06. The SSS suspension is great on the track and worth the extra cheddar in...
I have ridden both models, and I would go with the 06. The SSS suspension is great on the track and worth the extra cheddar in my mind
Fo sho...

The Shop

Lightning78
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10/16/2014 6:51pm
That helps A LOT thank you YamiRy239!
Crush
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10/16/2014 6:55pm
How'd you like the difference Yami?
Deetsmx
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10/16/2014 9:07pm
I also used 09 250f forks and did the same as yamiry239
2stroked
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10/17/2014 8:49am
There are a few items that seem to plague the 02-14 YZ125/250 two strokes.

In particular the shifter detent bearing. Yamaha lists it as the stopper lever assembly.

Part # 5CU-18140-01-00

This is the bearing that sits behind the clutch and pushes in and out against the shift drum as you go up/down. The problem is the original design. Its two open faced bearings sharing a common shaft that pushes in and out, and oscillates up and down. This completely stupid design creates wear on the races and they eventually flare and open out on the internal side of the case. This drops about 6-8 steel ball bearings inside the transmission and will literally destroy both cases and your entire transmission in a matter of seconds. You HAVE to shut down IMMEDIATELY as soon as you hear the slightest chatter.

On the YZ125 the design was changed a couple of years ago to solid steel wheels. However it didnt change on the YZ250. From what I've been told they finally updated the design on the '15 YZ250. The MSRP on this part is $30. Buy it and change it as soon as you buy the bike. This part will fail. Ive had this same part fail on both my different YZ125's, and about 30 hours in to my '13 YZ250. I'm one of those guys that changes his oil after every ride too, so maintenance is not an issue.


The stock airbox is a total POS. It will crack, it will split. Its happened on all my YZ's. Just keep an eye on it. Also the airbox doesnt seal that well, so make sure your air filter seats correctly on the base when you do your air filters. Ive had a lot of friends YZ's with the airboots covered in dirt from this issue. Not good when your carb is sucking dirt in.

Suspension wise the everyone says how 'stiff' the aluminum frame feels and can't get it plush like the steel frames. I disagree. My aluminum frame YZ's can feel just as plush as the steel frames. Its all in the setup. A little track I've noticed that helps calm the bike down is the high speed adjustment on the shock. Even for full moto, back it off. Its 2 3/4 turns lock to lock. Back it all the way out, then go in 1/2 turn and see how that feels. Gradually work back in until it feels 'harsh' through the frame. Then play with rebound and compression. Ive raced YZ's pretty much my whole life, I love them, they're a great bike. Hold out for a '09 or later IMO though, there are subtle changes after '08 that I really like compared to the 06-08.
Lightning78
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10/19/2014 10:22pm
So I took the plunge annnnnd picked up a 2003 YZ250, gott a say im pretty stoked on the bike. Gonna go through everything on it but the best part?

She's in incredible shape and I picked it up for the absurd price of $1,300!!! He wanted $1,600 and I told him I only had 1300 ....its a score! It also came with a step stand, has RG3 suspension, a PC shorty (to replace the PC spark arrestor)

Its gonna need a new rear tire, front and rear fenders, a white number plate, throttle cable (my preference) annnnd .....that covers it for now until I start putting the "goodies" on it



Lightning78
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10/19/2014 10:30pm
Parts to be added after the initial "fixes"

Tusk 270mm oversized front brake rotor
V-Force or Boyesen Reed valve assembly.....Thoughts or Opinions on either???
New PC Pipe
KYB "SSS" Suspension Swap
SDG Tall Seat
The "5XC-" super wide and stout footpegs that come on the late model WR's
Works Connection Frame Guards
New Rims - Not sure on the color Either Silver or Black..... Leaning towards silver bec the balck ones get hammered quickly
Factory Yamaha Style Graphics from around that time period


Am I missing anything else for those that know this bike well?
Crush
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10/19/2014 10:42pm
1300!!! Jealous!

Have you got tall seats on your other rides? I found it affected my cornering quite a bit.
Lightning78
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10/19/2014 10:52pm
Yea I was surprised he went for it, to be honest the bike was 2.5 hours away and I was getting anxiety about driving all that way based on just a pic, if it turned out to be a roach i wouldve been bummed so I told him I could only get 1300 out of my bank thinking he would pass and I would feel good about myself not going but he waited 30 mins and texted me back to come and get it...I couldnt pass that up........ it hasnt been ridden in 4 or 5 years form what I was told.

I have had them on a few bikes and im not sure if it affect my cornering BUY i am 6'4" so its kind of necessary for me. It doesnt need to be extremely tall but since im so used to them when I sit on a normal seat I feel like Im sitting in a saddle.
Lightning78
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10/19/2014 10:54pm
Crush, Im going to make it my main moto bike so its going to get a kings treatment, no bling just stuff that works and once im all set im going to have PC port that baby to run like a raped ape!

Either way it does need a new seat, im thinking he got scared of it because he looped it out which is evident from the back of the seat cover lol
10/19/2014 11:03pm
Nice buy. I've had good results from the V force but people seem to be going towards the Boyesen these days. Unsure on why. If your finding it a bit snappy and tiring or you ride a hard pack track, experiment with a little extra fly wheel weight. You may be suprised how much difference it makes to hook up and easier riding.
Lightning78
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10/19/2014 11:22pm
Nice buy. I've had good results from the V force but people seem to be going towards the Boyesen these days. Unsure on why. If your...
Nice buy. I've had good results from the V force but people seem to be going towards the Boyesen these days. Unsure on why. If your finding it a bit snappy and tiring or you ride a hard pack track, experiment with a little extra fly wheel weight. You may be suprised how much difference it makes to hook up and easier riding.
Yes I have pondered a FWW but I am coming off a 2006 RM250 for reasons unrelated to the bike and it was an absolutely amazing bike!! Still in pristine condition and for sale....that bike had a very light flywheel and would rev out quick but dam it made incredible power. I have ridden friends YZ250's in the past and the stock flywheel seems to be perfect for me but I will keep that in mind Underground, thank you.

Curious about the V-Force vs the Boyesen, I had a V-Force on the RM and it was a ripper but I really dont know the differences between the two with regards to performance and power characteristics....do you have any input Underground??
Crush
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10/19/2014 11:49pm
Raped ape! haha... oh dear.

V-Force is the way to go on the YZs. PC pipe and silencer. Squish and deck head...

I'm 6'6" and a bit... kept my KTM stock in terms of seat, flat bars, with risers in forward position and then lowboy pegs. It's actually pretty roomy! Ys you sit in a bit more tho...
10/20/2014 3:39am
I run the V-Force 3. I noticed the extra power in the mid-range right away. Get one - you can't go wrong.
Crush
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10/20/2014 5:03pm
I think in general the V-force is better for low and mid, and the boyesen is better for up top.

I had a boyesen in my 300, changed to v-force. Preferred V-force especially with pipe etc...
Lightning78
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10/20/2014 6:15pm
Hmmmm Im a mid-top rider so I may opt for the RAD Valve im going to have to ride it a few times first and see how the engine works...
Crush
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10/20/2014 6:22pm
Yeah might be worth it then. The response I found definitely crisper on the v-force... I guess because the way the petals are split up.
FGR01
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10/20/2014 8:21pm
The 5XC pegs are about 5mm lower than the stock 2-stroke pegs. Sounds like this might be a good thing for you. I used the 17D's from the newer 250F's on my YZ250 as they are the same height.

I have the stock reed cage on my 250. Haven't tried aftermarket but I did try a V-force on my YZ125 and it constantly leaked. Haven't heard of people having this prob on the 250 but I would say keep an eye on it and seal it good with Moto-seal or other gas-proof sealant.

On the shift stopper, it is a pretty common prob for it to come apart on the 125, but doesn't seem as common on the 250 for some reason. I just checked the part number and the 2015 YZ250 has the same part number as previous years.

Why a new PC pipe? Isn't that a PC pipe on it? Just remove the black paint.

Not sure if the 2006+ seat fits on the 2003 but if it does, it is slightly taller, flatter front to rear, and has a more rounded profile side to side. Doesn't feel as sway back as the older bikes.
10/20/2014 10:28pm
My friend is 6'5", he modded the stock pegs like this- http://www.thumpertalk.com/topic/434905-lowering-stock-foot-pegs-05/ on his 03 WR450. He said it really helped open the bike up, made a nice difference in comfort for him.

Other threads on Yamaha footpegs: http://www.thumpertalk.com/topic/791880-yamaha-oem-foot-pegs-peg-loweri… http://www.thumpertalk.com/topic/747661-wider-and-lower-foot-peg-diy/
2stroked
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10/21/2014 9:33am Edited Date/Time 10/21/2014 9:41am
FGR01 wrote:
The 5XC pegs are about 5mm lower than the stock 2-stroke pegs. Sounds like this might be a good thing for you. I used the 17D's...
The 5XC pegs are about 5mm lower than the stock 2-stroke pegs. Sounds like this might be a good thing for you. I used the 17D's from the newer 250F's on my YZ250 as they are the same height.

I have the stock reed cage on my 250. Haven't tried aftermarket but I did try a V-force on my YZ125 and it constantly leaked. Haven't heard of people having this prob on the 250 but I would say keep an eye on it and seal it good with Moto-seal or other gas-proof sealant.

On the shift stopper, it is a pretty common prob for it to come apart on the 125, but doesn't seem as common on the 250 for some reason. I just checked the part number and the 2015 YZ250 has the same part number as previous years.

Why a new PC pipe? Isn't that a PC pipe on it? Just remove the black paint.

Not sure if the 2006+ seat fits on the 2003 but if it does, it is slightly taller, flatter front to rear, and has a more rounded profile side to side. Doesn't feel as sway back as the older bikes.
The V force 3 cage leaks, period. Some people get lucky yes, but that is the exception to the rule. The rule is it leaks, period. The trick I've found is ordering two reed cage gaskets, and putting one on both sides, and coat both sides of the gasket with yamabond 4, the same stuff yamaha makes to seal the cases. I've done this trick on both my YZ125's and on my YZ250 as well.

As for the shift stopper, well yamaha didnt change the part number on the 125 either. Then magically it starting coming out as solid steel wheels instead of the bearing type. Ive spent hours on the phone with yamaha directly, and even showed them the photo's of the same parts failing over and over in different bikes. Typical corporate response of its not an issue we're aware of, there is no service bulletin, and no recall on the part. It must be something you're doing sir. Give me a break.





That happened on my 2013 YZ250 with just over 30 hours on it. Ordered a new one, and the replacement part was still the bearing design. The 125 has solid steel wheels. I'd have to order another one to see if the part has actually changed on the 250. In the meantime I replace this part about 20 hours.
FGR01
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10/21/2014 9:48am
Actually, the part number did change for the 125 when it went to a solid steel wheel in 2007. The new part then became the superseded part for the older 2005-2006 bikes. So they updated the parts diagrams for all the older bikes so that if you ordered a shift stopper you would automatically get the updated part.

Perhaps they have done this with the 2015 YZ250 part and that is why the parts diagrams for the older bikes show the same number. I hope so. You've got me scared now and I want a solid wheel version in my 250 ! Let us know what you get if you order one.
YamiRy239
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10/21/2014 5:49pm
Crush wrote:
How'd you like the difference Yami?
The difference was very noticeable. I only raced it twice this season and practiced once, so I didn't put a lot of seat time on it. Its super plush now, and combined with the steel frame it seems to soak up everything. I have a '13 YZ250 as well that is my primary race bike. When switching between the two it is very apparent how much more rigid the aluminum frame is.

Lightning78
I put a GYTR off-road flywheel on my '13 over the weekend and rode a friends track. Let me tell you I'm definitely going to put one on my '03 as well! Its amazing how linear the power is now. I had the head mod done on the '13 at the beginning of this season. (squish set to .044", chambered for race fuel) that made a word of difference, and it pulls really hard. Almost to hard because I was having trouble getting traction in tight corners. Now with the flywheel it is putting the power to the ground. It helped my corner speed without a doubt.
dedi684
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10/21/2014 6:28pm
I have a shit load of new and used YZ 125\250 parts for sale.
Rg3 top clamp
Complete oem seat new
Used pc shorty silencer
Universal eng top triple clamp (was on my 2002)
New oem rear fender and front plate
Lightning78
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10/21/2014 9:40pm
Crush wrote:
How'd you like the difference Yami?
YamiRy239 wrote:
The difference was very noticeable. I only raced it twice this season and practiced once, so I didn't put a lot of seat time on it...
The difference was very noticeable. I only raced it twice this season and practiced once, so I didn't put a lot of seat time on it. Its super plush now, and combined with the steel frame it seems to soak up everything. I have a '13 YZ250 as well that is my primary race bike. When switching between the two it is very apparent how much more rigid the aluminum frame is.

Lightning78
I put a GYTR off-road flywheel on my '13 over the weekend and rode a friends track. Let me tell you I'm definitely going to put one on my '03 as well! Its amazing how linear the power is now. I had the head mod done on the '13 at the beginning of this season. (squish set to .044", chambered for race fuel) that made a word of difference, and it pulls really hard. Almost to hard because I was having trouble getting traction in tight corners. Now with the flywheel it is putting the power to the ground. It helped my corner speed without a doubt.
I totally feel ya on the steel vs aluminum frames....when ridden back to back it unbelievable how harsh and NOTICEABLE it is. If someone is used to their bike then they'll tell you how they hardly notice but do a back to back with any 2000 and up steel framed MX bike. Advocates and magazines will tell you how much better aluminum frames have gotten which is totally true from the 1st gen designs from ANY Mfg but IMHO they are nowhere near a steel frame feeling. The contradiction is that we just want the steel frame to be slightly more rigid than is logically possible to build and make functional or we (riders) want an aluminium frame to feel slightly LESS rigid than the current designs, again, not logically possible due to material strength as compared to chromoly steel and fatigue in minimizing design bec I may be wrong on this but the range of allowable flex before breakage on an aluminum frame is much less than that of steel?


YamiRY239 .... Im coming off an 06 RM250 (dont ask) im bummed about it, I will consider a FWW now that I think about what you said and the RM has basically an identical engine to the YZ hell even their pistons are interchangeable lol... and that bike had (stock)( a flywheel much lighter than the YZ so I was going to add 6-9oz bec I really like the lightning (pun intended) lol snap power of the RM but it just needed to be tamed down a little as it would rev out SO FAST that I had to shift a lot fo that extra 20', having ridden a couple yz's I know they have a heavier flywheel with a more tractable powerband but I may go 6oz depending on how she runs but I really appreciate the advice.

BTW the front wheel seems to have a little vertical camber to it and spins freely but rubs heavily on the brake caliper but yes it does spin freely ....is it possible for the forks to be that twisted from a crash or should I be really concerned??? I am going to pull the bike front to rear apart this weekend and go through it....any advice on why it would be that twealed it also has a really big rock dong on the front rim I didnt see before the seller told me about it over the phone but I forgot to look

I cant wait to ride this bike!!!!!!
Lightning78
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10/21/2014 9:45pm
FGR01 wrote:
The 5XC pegs are about 5mm lower than the stock 2-stroke pegs. Sounds like this might be a good thing for you. I used the 17D's...
The 5XC pegs are about 5mm lower than the stock 2-stroke pegs. Sounds like this might be a good thing for you. I used the 17D's from the newer 250F's on my YZ250 as they are the same height.

I have the stock reed cage on my 250. Haven't tried aftermarket but I did try a V-force on my YZ125 and it constantly leaked. Haven't heard of people having this prob on the 250 but I would say keep an eye on it and seal it good with Moto-seal or other gas-proof sealant.

On the shift stopper, it is a pretty common prob for it to come apart on the 125, but doesn't seem as common on the 250 for some reason. I just checked the part number and the 2015 YZ250 has the same part number as previous years.

Why a new PC pipe? Isn't that a PC pipe on it? Just remove the black paint.

Not sure if the 2006+ seat fits on the 2003 but if it does, it is slightly taller, flatter front to rear, and has a more rounded profile side to side. Doesn't feel as sway back as the older bikes.
Hey FGR I had plans to strip the paint off but he told me he went and sanded it to get the paint to stick well so Im concerned it will look like shit because the paint is stuck on there gppd and it was done very well although I would really like to remove it if I could......what does everyone recommend for what I assume to high temp exhaust paint to completely strip the paint off of the pipe with ease????????????/

There is some kind of "Airplane stripper" paint remover Ive read and heard about....anyone have some examples or recommendations on what to use to get that pipe back to a works bare metal finish bec I REALLY want to get that pipe back to glory and also remove one dent in the head part of the pipe....easy dent removeal tips????
Lightning78
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10/21/2014 9:49pm
dedi684 wrote:
I have a shit load of new and used YZ 125\250 parts for sale. Rg3 top clamp Complete oem seat new Used pc shorty silencer Universal...
I have a shit load of new and used YZ 125\250 parts for sale.
Rg3 top clamp
Complete oem seat new
Used pc shorty silencer
Universal eng top triple clamp (was on my 2002)
New oem rear fender and front plate
Nice I could really use

Either the RG3 or Universal clamp
The OEM seat
Rear Fender and Front plate

Dude looped it out abd the back of the seat cover is ground down enough to have a tear the width of the seat and the rear fender looks bad too, fronty one os cracking,,,,,this bike sat for over 4 years so im curious what else Ill find lol

I have a PC shorty thats going on this weekend!! whoo!!

send me a PM and lets talk!
FGR01
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10/22/2014 7:17am
Hey FGR I had plans to strip the paint off but he told me he went and sanded it to get the paint to stick well...
Hey FGR I had plans to strip the paint off but he told me he went and sanded it to get the paint to stick well so Im concerned it will look like shit because the paint is stuck on there gppd and it was done very well although I would really like to remove it if I could......what does everyone recommend for what I assume to high temp exhaust paint to completely strip the paint off of the pipe with ease????????????/

There is some kind of "Airplane stripper" paint remover Ive read and heard about....anyone have some examples or recommendations on what to use to get that pipe back to a works bare metal finish bec I REALLY want to get that pipe back to glory and also remove one dent in the head part of the pipe....easy dent removeal tips????
You can try paint stripper like Aircraft stripper or Zip-Strip. If the paint he used was soft it might take most of it off. I tried this once and it barely removed any paint and it's a PITA because you have to wear gloves and the crap gets all over. I ended up using a small wire wheel on an electric drill and that took it right off. Afterwards, I sanded it with increasingly fine grades of sandpaper and steel wool to get a nice smooth finish.

The best way to remove dents is to cap both ends of the pipe, one cap with a schraeder valve and then pressurize the pipe. Start with about 40psi and try not to go higher but I have gone up as high as 90psi. Then heat the dent area with a MAPP gas torch until it is cherry red. The metal will get soft and the air pressure will expand and push the dent out. Sometimes it works perfect and other times it works so-so if the edge of the dent has a hard crease. While you're at it, you could just use the torch to burn all the paint off.

If you don't feel like sourcing the caps and all that one of the pipe repair places is your best bet. They will remove the dent and the paint and then you'd just have to sand it and make it look nice.

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