1996 YZ250

RABnasty
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RABnasty
Edited Date/Time 4/21/2020 10:09am
Hey Fellow Vitards. Scooped up another project today. Going to need some help.
Never owned a Yamaha. Primarily going to need help finding a gas tank. I think I want
to go with a updated like 1999 MC style look.



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RABnasty
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Temecula, CA US
RABnasty 5/6/2019 2:10am
5/6/2019 2:10am
Alright guys, its my night off from work. Got the YZ home tonight and a couple of silver bullets later decided, why not tear it down. So here is the first few steps of the tear down took about an hour to get to this point.

The plastics are faded and garbage they are going in the trash.


I have a feeling these are original tires on the bike, which for me is always a good sign.


The Bud Light graphics just scream 90's moto.










How do dents like this even happen?











Could not believe this thing had a clean air filter!!!!



This top clamp is pretty cool!


I don't think this pipe is going to be worth fixing.



Clean and full of coolant, also a good sign.




This is as far as I got in the first night. Hopefully this week can get it completely torn down and sent out for powder coat. I have new cosmetic stuff on the way, including a gas tank. Going to get the suspension freshened up and replace all linkage and neck bearings seals etc. Just want to bring her back to life!





Last little tid bit. Cool surprise the bike has what looks like a barely ridden Wiseco piston. Does anyone have any idea what this "N" stands for. Found that to be interesting.





Thank you for checking out my build so far. Will try to update this weekly.
3
sandman768
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sandman768 5/6/2019 4:41am
5/6/2019 4:41am Edited Date/Time 5/6/2019 4:42am
Cool bike, PC foot pegs? I think that’s a Namura piston, who ever rebuilt it bought the cheap stuff, tear it down & get that piston out of there...
2
DTR830
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DTR830 5/6/2019 9:38am
5/6/2019 9:38am
RABnasty wrote:
Alright guys, its my night off from work. Got the YZ home tonight and a couple of silver bullets later decided, why not tear it down...
Alright guys, its my night off from work. Got the YZ home tonight and a couple of silver bullets later decided, why not tear it down. So here is the first few steps of the tear down took about an hour to get to this point.

The plastics are faded and garbage they are going in the trash.


I have a feeling these are original tires on the bike, which for me is always a good sign.


The Bud Light graphics just scream 90's moto.










How do dents like this even happen?











Could not believe this thing had a clean air filter!!!!



This top clamp is pretty cool!


I don't think this pipe is going to be worth fixing.



Clean and full of coolant, also a good sign.




This is as far as I got in the first night. Hopefully this week can get it completely torn down and sent out for powder coat. I have new cosmetic stuff on the way, including a gas tank. Going to get the suspension freshened up and replace all linkage and neck bearings seals etc. Just want to bring her back to life!





Last little tid bit. Cool surprise the bike has what looks like a barely ridden Wiseco piston. Does anyone have any idea what this "N" stands for. Found that to be interesting.





Thank you for checking out my build so far. Will try to update this weekly.
Namura pistons
RABnasty
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RABnasty 5/6/2019 2:38pm
5/6/2019 2:38pm
Thank you guys for the heads up on the piston. Got the bike down to the frame today and pressure washed everything. Will be dropping the frame off for powder coat here in the next week. Thank you guys for looking.


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RABnasty
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RABnasty 5/8/2019 10:59am
5/8/2019 10:59am
Small update. Upon inspection of the frame if you look closely the left side of the photo. There are a few holes. Going to have this frame rebuilt and reinforced before I send it off for powder coating. Doesn’t really surprise me I was expecting to run into things like this along the way.
sandman768
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sandman768 5/8/2019 12:42pm
5/8/2019 12:42pm
Surprised to see this on a California bike, assuming that’s where you are. My only concern would be; is it rusting from the inside\ out? while those lower tubes can be replaced & reinforced, the left outer tube worn through is a bit of concern, that is usually a very thick area, you may want to see if you can find a cleaner frame.
RABnasty
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RABnasty 5/8/2019 5:55pm
5/8/2019 5:55pm
sandman768 wrote:
Surprised to see this on a California bike, assuming that’s where you are. My only concern would be; is it rusting from the inside\ out? while...
Surprised to see this on a California bike, assuming that’s where you are. My only concern would be; is it rusting from the inside\ out? while those lower tubes can be replaced & reinforced, the left outer tube worn through is a bit of concern, that is usually a very thick area, you may want to see if you can find a cleaner frame.
Thanks for the heads up, yes I am in California! But this bike was relatively close to the ocean and I have a feeling it’s been sitting for a looooong time.
RABnasty
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RABnasty 5/8/2019 11:49pm
5/8/2019 11:49pm
Another night killing time in the garage did some cleaning on the motor.

Before



First bit of cleaning still have a ways to go.
After

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mxer613
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mxer613 5/9/2019 8:02pm
5/9/2019 8:02pm
Here’s mine I did last fall, has less than 15 original hours!
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RABnasty
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RABnasty 5/9/2019 11:28pm
5/9/2019 11:28pm
mxer613 wrote:
Here’s mine I did last fall, has less than 15 original hours! [img]https://p.vitalmx.com/photos/forums/2019/05/09/345807/s1200_57571F0B_7CE8_4714_97BC_BF110AD92D8F.jpg[/img]
Here’s mine I did last fall, has less than 15 original hours!
Bike is stunning man! Wish I could’ve gotten one that clean! I like how you kept the original look! I am going with a different look but I dig the stock set up.

Speaking of which, I’ve heard mixed reviews about these Clarke tanks. Maybe I got lucky, this tank quality is much better than the Cycra that was on the bike. All of the hardware lined up perfect. I have a fabricator that is going to look at my frame tomorrow hopefully that works out. I’m switching career paths, this build might slow down for a month or two but I will do my best. Thanks for looking! Here is the tank.


2
RABnasty
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RABnasty 5/10/2019 11:54pm
5/10/2019 11:54pm
Got the frame inspected and welded up today, will be sending it for powder next week. Got a seat cover off eBay for 10 bucks lol.

1
RABnasty
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RABnasty 5/16/2019 11:26pm
5/16/2019 11:26pm
Convinced the wife to put my graphics on!



I'm not going for the OEM look or a full Replica build. Just want something that looks period correct and is fun as hell to ride. So far I am pretty stoked on how its coming along. For the amount of money I have spent it will be impossible not to enjoy this thing!

8
Lasse
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DK
Lasse 5/17/2019 4:37am
5/17/2019 4:37am
Following this one for sure!
1
smashingpumpkins167 5/17/2019 11:42pm
5/17/2019 11:42pm
The picture of the tank with the chaparral stickers in the fender kind of reminded me of this picture. I remember him riding a yamaha that basically had stock graphics with the chaparral sticker over it


1
RABnasty
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RABnasty 5/18/2019 5:20pm
5/18/2019 5:20pm
smashingpumpkins167 wrote:
The picture of the tank with the chaparral stickers in the fender kind of reminded me of this picture. I remember him riding a yamaha that...
The picture of the tank with the chaparral stickers in the fender kind of reminded me of this picture. I remember him riding a yamaha that basically had stock graphics with the chaparral sticker over it


I think I’m going with the number 2 as well should turn out pretty sweet!
RABnasty
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RABnasty 6/30/2019 3:08pm
6/30/2019 3:08pm
Finally sent the Frame to powder, excited to get working on this thing again! I went ahead and stripped the subframe for a raw look. I am going to be working on the swing arm this week getting it cleaned up and re greased. Will post a pic when the frame gets here, cheers!!
RABnasty
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RABnasty 6/30/2019 5:01pm
6/30/2019 5:01pm
Got the swing arm bearings all cleaned and greased up and gave the swing arm a good cleaning. Didn’t get too crazy with polishing it, more of a brushed look but i think it still looks good.
RABnasty
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RABnasty 7/1/2019 1:06am
7/1/2019 1:06am
A previous owner tried to use some weird silicone or something to try and fix some cracks in the air box.



I used my soldering iron and an old black plastic bottle cap to fill in the cracks so it’s much stronger now. Wasn’t the prettiest but luckily the graphics cover it up. I think it cleaned up nice. Can’t wait to get my frame!


1

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RABnasty
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RABnasty 7/9/2019 6:52pm
7/9/2019 6:52pm
Still waiting on bearings and seals and all kinds of things but it’s starting to look like a motorcycle again



12
RABnasty
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RABnasty 9/4/2019 4:40pm
9/4/2019 4:40pm
Sorry it’s been a while, started my own business and it’s been crazy. Finally dropped the forks off and got working on some little things. Bike runs super good but the carb is leaking, going to need a new bowl.

I do have one question that I can’t really figure out, if any of you guys have worked on these before, it’s kind of silly. The seat and the plastics all mount off off the same bolt. But it’s not threaded on the subframe and obviously impossible to put a nut under the seat. Am I retarded or is there some trick to this?




Here is the small progress I made, all new steering bearings and cleaned up the clamps. Put some of the controls on and she fired up nice!


4
RABnasty
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RABnasty 9/5/2019 8:27pm
9/5/2019 8:27pm
Well I’ve got myself a roller! Going to take it to a welder tomorrow and get a couple small things cleaned up. Gonna order a pipe this week and send the wheels over to the guys at FasterUSA to get freshened up
6
Banana_oil
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Gothenburg SE
Banana_oil 9/6/2019 7:10am
9/6/2019 7:10am
There should be welded nuts at the seat mounts
RABnasty
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RABnasty 9/6/2019 5:02pm
9/6/2019 5:02pm
Banana_oil wrote:
There should be welded nuts at the seat mounts
Thanks! I dropped it off at a welder today to get everything cleaned up! Also picked this beauty up



5
RABnasty
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RABnasty 9/8/2019 11:15am
9/8/2019 11:15am
Starting to see the light at the end of the tunnel, just need wheels/tires, brakes, and a clutch


6
Chance1216
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Chance1216 9/8/2019 11:54am
9/8/2019 11:54am
I like that Buds silencer. Hard to tell how nice it is on their site. Your pics did it justice. Now I want one. Thanks lol
RABnasty
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RABnasty 9/8/2019 1:53pm
9/8/2019 1:53pm
Chance1216 wrote:
I like that Buds silencer. Hard to tell how nice it is on their site. Your pics did it justice. Now I want one. Thanks lol
It has a really cool adjustable mount that is easy to use and the quality of everything is really good. Sound is crisp as well I’m stoked on it
1
450exc115
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Hebron, CT US
450exc115 9/10/2019 7:11am
9/10/2019 7:11am
Nice bike and build. My first brandy new bike was a 98 YZ250 which is very similar. I'm actually trying to get it back from the guy i sold it to in 2001 who still has it!

MC ran a 94 cylinder on his Supercross bike before the 99 and newer motor was released. It had more bottom and mid than the later 96-98 cylinders with the volume chamber on the side of the PV. There were even blank off plates you could get for the 96-98 to help with low/mid power. I called PC about the 94 cylinder swap (they did his motors) and asked about it and they would build a cylinder for me for $800 which included new NOS cylinder/PV and PC porting. They also said the mere mortals probably couldn't tell the difference between a ported 94 or ported 98 cylinder. LOL

I had my 98 ported by Noleen, matched the cases and ran a Noleen pipe on it when I was riding Moto. Bike ripped, more power everywhere with a nice long top end pull. Rear suspension can be made to work really well and Yamaha hasn't strayed much from that linkage ratio for the last 20 years. Swap the forks for the later KYB 48s or even the SSS versions on the 06 and up if you want to make it even better. The late 90s early 00s 46mm forks use shock bumper for bottoming control and aren't as nice as the hydro stops that come on the 48s.

Cool bike and enjoy!

1
RABnasty
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RABnasty 9/10/2019 9:23am
9/10/2019 9:23am
450exc115 wrote:
Nice bike and build. My first brandy new bike was a 98 YZ250 which is very similar. I'm actually trying to get it back from the...
Nice bike and build. My first brandy new bike was a 98 YZ250 which is very similar. I'm actually trying to get it back from the guy i sold it to in 2001 who still has it!

MC ran a 94 cylinder on his Supercross bike before the 99 and newer motor was released. It had more bottom and mid than the later 96-98 cylinders with the volume chamber on the side of the PV. There were even blank off plates you could get for the 96-98 to help with low/mid power. I called PC about the 94 cylinder swap (they did his motors) and asked about it and they would build a cylinder for me for $800 which included new NOS cylinder/PV and PC porting. They also said the mere mortals probably couldn't tell the difference between a ported 94 or ported 98 cylinder. LOL

I had my 98 ported by Noleen, matched the cases and ran a Noleen pipe on it when I was riding Moto. Bike ripped, more power everywhere with a nice long top end pull. Rear suspension can be made to work really well and Yamaha hasn't strayed much from that linkage ratio for the last 20 years. Swap the forks for the later KYB 48s or even the SSS versions on the 06 and up if you want to make it even better. The late 90s early 00s 46mm forks use shock bumper for bottoming control and aren't as nice as the hydro stops that come on the 48s.

Cool bike and enjoy!

Thank you for all of your insights! I would love to swap my forks but don’t want to swap out my wheel and brakes and all the other stuff that goes with it.
RABnasty
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RABnasty 9/16/2019 3:06pm
9/16/2019 3:06pm
Here is some drool worthy bling from the guys over at Faster USA.

Wheels Before



Wheels After



Haven’t received my clutch in the mail yet, but the guys over at Faster coated my clutch cover for me. Here is a mock up!



7
RABnasty
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RABnasty 9/16/2019 6:14pm
9/16/2019 6:14pm
It’s getting so close! I’m almost getting tired of working on this thing lol. I will get it out in the sun for a better pic tomorrow... have a feeling I will get this thing dirty in a couple weeks Smile


7

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