2003 YZ250 Build - The Steely

slackinoff wrote:

Hey what's up Doc? I would say it depends on the type of riding you do. If I was just doing off road stuff, I think...

Hey what's up Doc?

I would say it depends on the type of riding you do. If I was just doing off road stuff, I think the 02 forks are just fine. But I will say, I do like my SSS forks even better than the OC forks off road....just slightly. The big difference for me was on the MX track with bigger jumps that pucker this novice's butt up. The pucker factor is definitely lower now.

Andrew337 wrote:

I'll jump into this discussion a little bit with my findings. I consider myself a C class motocross rider, B class off-road, around 165lb without gear...

I'll jump into this discussion a little bit with my findings. I consider myself a C class motocross rider, B class off-road, around 165lb without gear, and just recently have started trying to focus on suspension. I rode the bike for about a year with the stock 46mm forks. I now have three rides on my SSS forks on an '02 YZ250, as far as I know the forks have the stock springs and valving for an '06 YZ125. I never had much issue with stability on jump faces, but I was fighting headshake in high speed braking bumps with the old setup. I tried running more sag, lowering the fork tubes in the clamps, slower shock rebound, stiffer fork compression and faster rebound, everything I could try to keep the front stable in choppy bumps. Nothing helped with the headshake and cornering suffered. The original forks were freshly rebuilt and revalved with Race Tech Gold Valves, stock springs, and OEM bushings and seals.

I was concerned that I would still have headshake issues with the SSS forks because they have softer springs in them, but that hasn't been the case. I set the bike up to a much more "normal" setting for sag and fork tube height, and the headshake is all but gone. Right off the bat I could tell there was less friction in the forks. The biggest improvement aside from eliminating headshake was in cornering, I can duck to the tightest inside line with ease, and make mid-corner corrections with much more precision. I feel like I can really charge into a corner and pick and choose a line, and the bike will go there. In my mind I attribute this to the softer springs and generally plusher SSS forks. I also notice that I use more of the stroke, with the old open chamber forks I would never use the last 2-3" of travel. I attribute this to the softer springs and just being able to ride harder with the SSS forks.

Take that for what it's worth, I'm not a very good test rider but I'm trying to really pay attention to what the bike is doing and learn to make logical adjustments and notice the difference. Also note that I swapped to an Ohlins shock at the same time, so that also factors into how the bike is handling now. I have about $700 invested in this total suspension makeover (not counting resale value of the stock forks and shock) and I've been very very happy with the results.

slackinoff wrote:

Awesome! 345 is great. I got mine 4 310, ebay shipped for the 06 yz450f forks, triple, and guards. Took a gamble though for sure. Pics...

Awesome! 345 is great. I got mine 4 310, ebay shipped for the 06 yz450f forks, triple, and guards. Took a gamble though for sure. Pics sucked. So happy they were great in person.
Anyone need 06 yz450f triples? Bearings ok on lower stem.

slackinoff wrote:

I have been working on this project for a couple of months. Snapping pics as I go, so enjoy those as I get this thread up...

I have been working on this project for a couple of months. Snapping pics as I go, so enjoy those as I get this thread up to date.

Here is the story. I am currently 26. My best friend and I rode 80s , his dad drove us everywhere, it was awesome in one single word. Dads – those are the best times ever, even if we are a pain in the ass and are shit heads, we will remember those days with lots of love. Thank you.

We both “Hung” up the boots as they say as soon as we turned 16 and started chasing girls around. Rediscovered the sport when I was about 24. First bike back was a 02 CR125, next bike was a YZ426, then I went all out and picked up a 2014 YZ250f. Loved that bike….but I eventually realized that I don’t need that kind of money tied up in a dirtbike to enjoy the sport.

#1


#2


#3 Sold today (7/16/15), happy to get out from under that debt! I will miss this bike though, superb power and handling


I don’t race much, but when I do it’s totally for fun, just like any track day. So yeah, when my buddies 2003 yz250 lost the airboot and sucked a ton of dirt in….I was waiting like a vulcher for him to sell it to me cheap. I think this is the perfect “long term play rider” bike. There is a decade of parts built up on the planet that will keep the costs low and easy to maintain for a long term.


Here we go!

I don't have many"before" of the YZ250 but this will give you a general idea of the bike. Everything was not too bad except the motor and the wheels. Which were just horrible. Motor was toast, every spoke nipple seized.



Look at that sand paste!! Ouch










I could not find my flywheel puller so I rigged up the case splitter in a way that grabbed the flywheel. Took like 5 attempts to get right.



Clutch outer cover side was really nice condition, zero wear on the basket and the gears



Got the cases split and trans out.




This was terrifying but I got it out no problem



Pulled every bearing and seal out of the cases and then sent the cases off to get vapor blasted. 65 bucks later and I am as happy as happy as the proverbial pig in shit. Will post these pics tommorrrow!!! stay tuned