Guzzi's Oz 1995 YZ250 full rebuild finally runs :)

guzziboy532 3/23/2022 5:04pm
3/23/2022 5:04pm
Finally got my suspension back after almost two years of constant lockdowns. To say Darren did a great job is an understatement. Swapped in some newer YZ internals on the shock to replace the damaged chrome and also did springs front and back. It’s set up for my weight and (poor) ability now.


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guzziboy532 3/23/2022 5:07pm
3/23/2022 5:07pm
Have started building wheels with freshly cerakote stock hubs laced with excel spokes to SM Pro rims. Going to look amazing. 🤌🏼👌


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guzziboy532 3/23/2022 5:11pm
3/23/2022 5:11pm
So in order to repair the dodge repair done on the sump pump plug, I though Fk it, might as well do the bottom end whilst I am there so next minute 😆🤷‍♀️😲

Glad I did this, it’s actually in really good shape, just a few of the tranny bearings that need doing. The big end is pretty good but obviously has some hours on it. Primary drive gear is cactus so have found a second hand one. Have ordered genuine bearings, and have sent the crank off for new Conrod kit and balance.

Plan is to clean the cases out and do some more sexy cerakote whilst I’m there #NowIampoor


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Pirate421
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Pirate421 3/23/2022 5:29pm
3/23/2022 5:29pm
Wow that frame was a mess nice job on the repair. I think I would have just looked for a new frame!

The Shop

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guzziboy532 3/24/2022 11:35pm
3/24/2022 11:35pm
Pirate421 wrote:
Wow that frame was a mess nice job on the repair. I think I would have just looked for a new frame!
Was thinking about it mate and looked hard for one, the WR up to 97 i think kept this frame but finding one here was impossible. After talking to some guys on the VMX scene on facebook here I quickly learnt they all rust here due to the water sitting in the bottom of the frame. Thus, the grinder and TIG were deployed!
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guzziboy532 3/29/2022 11:02pm
3/29/2022 11:02pm
After many hours of head scratching and zero experience welding aluminium I decided to try and ruin my cases by fixing the cracked oil plug myself. I started by removing this pile of JB Weld and thread tape pile of PUSS



Then I ground out more JB Weld, thread tape, gasket goo and PUSS left by previous owner to get to clean metal



I then degreased, pressure washed, acetone cleaned, heated, acetone cleaned some more, heated some more, grinder and drank a beer before going for the plunge. I totally fluked it and had decent castings that didn’t produce a heap of crap. After some more swearing and a HEAP of hand filing, it resembles something like original

👍




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Ryan598
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Ryan598 4/3/2022 9:46am
4/3/2022 9:46am
guzziboy532 wrote:
Finally got my suspension back after almost two years of constant lockdowns. To say Darren did a great job is an understatement. Swapped in some newer...
Finally got my suspension back after almost two years of constant lockdowns. To say Darren did a great job is an understatement. Swapped in some newer YZ internals on the shock to replace the damaged chrome and also did springs front and back. It’s set up for my weight and (poor) ability now.


Did you have to go with heavier springs in the forks? I have a 1994 I did a restore to last year. I weigh about 250. Can’t find any fork springs at all. Apparently those forks had an odd ball spring size.

I was even directed to a company that makes springs and they said they couldn’t make me any for that fork. My bike has springs in it so soft that it is nearly unrideable for me.
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guzziboy532 4/9/2022 10:12pm
4/9/2022 10:12pm
guzziboy532 wrote:
Finally got my suspension back after almost two years of constant lockdowns. To say Darren did a great job is an understatement. Swapped in some newer...
Finally got my suspension back after almost two years of constant lockdowns. To say Darren did a great job is an understatement. Swapped in some newer YZ internals on the shock to replace the damaged chrome and also did springs front and back. It’s set up for my weight and (poor) ability now.


Ryan598 wrote:
Did you have to go with heavier springs in the forks? I have a 1994 I did a restore to last year. I weigh about 250...
Did you have to go with heavier springs in the forks? I have a 1994 I did a restore to last year. I weigh about 250. Can’t find any fork springs at all. Apparently those forks had an odd ball spring size.

I was even directed to a company that makes springs and they said they couldn’t make me any for that fork. My bike has springs in it so soft that it is nearly unrideable for me.
Yeah mate he put heavier springs front and rear it’s basically a setup 03 yz250 now 😉
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guzziboy532 4/9/2022 10:15pm
4/9/2022 10:15pm
So I wanted to fix this chain guard post before I send the cases off for cerakote. This bolt just makes me nervous with this dodge repair, there’s no meat on the aluminium here


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guzziboy532 4/9/2022 10:17pm
4/9/2022 10:17pm
You can see she’s had a few chains off in a previous life so more swearing, and some nervous dremel work and filing


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guzziboy532 4/9/2022 10:19pm
4/9/2022 10:19pm
The plan was to file this flat and then weld on some round stock but getting the metal to cooperate so close to the clutch race (it’s sooooooo thin here) was to difficult


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guzziboy532 4/9/2022 10:23pm
4/9/2022 10:23pm
So I just built up the entire post with weld, washing the aluminium into the delicate areas. More swearing, filing and dremel work. Drill and a tap and it turned out awesome 👏


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guzziboy532 10/3/2022 2:58am
10/3/2022 2:58am
Hard to believe two years has gone past but here we are. Many beers and head scratching have been allocated in the shed in the last few weeks whilst starting the long road to riding this thing again.

Where were we again? Oh yeah so I paid a visit to Mr LA Designs to have my crusty cases loved a little

Before:



After



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guzziboy532 10/3/2022 3:04am
10/3/2022 3:04am
After finally getting a full genuine bearing set together I gently persuaded the newly balanced crank with its sexy sister mrs wossner back into the cases. Mind you, your stock crank pulled kit won’t work on these old girls as there is no thread in the gearbox side of the crank in which to attach to, so the primary drive gear was donated along with a little bush welding



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guzziboy532 10/3/2022 3:08am
10/3/2022 3:08am Edited Date/Time 10/3/2022 3:10am
I found this rebuild video invaluable in putting mine back together after a year of it sitting on the bench

https://m.youtube.com/watch?v=wUkGTRaU0GQ

And this guys tedious videos were so detailed there was no way to miss anything. If your doing a 93-95 this is the bible

https://youtu.be/C-_B8PLR4ts

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guzziboy532 10/3/2022 3:14am
10/3/2022 3:14am
I have spent at least five hours re-splitting the cases to get things to work which is standard dumb f$$k behaviour of someone with my skill level. Now waiting for two dowels to
come all the way from Japan because they were lost in top and bottom end transits across the country😂😂😂🤦‍♀️🤷‍♀️🤯


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Pit Row

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guzziboy532 10/7/2022 9:49pm
10/7/2022 9:49pm
Getting there
Need plastics, sticker kit, rubber, still waiting on Yamaha parts for barrel and head…


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guzziboy532 10/19/2022 3:39am
10/19/2022 3:39am
Battling brakes at the moment. Much more swearing and pacing around shed has taken place. Trying to mate brand new later model Nissin Master Cylinder to two different braided lines either of which are correct length, shape or have correct fittings.

Reckon this rear rotor might need replacing? 😂😂😂🤦‍♀️


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guzziboy532 11/18/2022 10:04pm
11/18/2022 10:04pm Edited Date/Time 11/18/2022 10:06pm
Taking 5 steps forward and 15 steps back at the moment 🤯 waiting for worlds slowest order of OEM parts before I can tighten up things. Have been pulling my hair out trying to get brakes to work. Every time I put something together I find something else that’s either flogged out, missing or not available to purchase.

This time it’s the mounts that hold the rear brake (pins with horizontal grooves) I’ve lost one somewhere along the build. Unobtainable. Not even listed as a part on the Fische as it’s part of the caliber itself. Got an eBay special one that will work with a little drilling and clean up of the original hole. She’s sloppy 😂😂😂😂😱🤷‍♂️🤷‍♂️🤷‍♂️



Next problem is the actual plate that everything sits on that your axle goes through is so roooooted, that the thing hangs down too low and the banjo bolt will be smashing off the top of my swing arm. You can see why they changed this design on later models. So out came the Tig again and tried to get the oil stained aluminium to weld which wasn’t easy. Fourteen hours with a hand file and it’s almost useable again







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guzziboy532 3/26/2023 12:17am
3/26/2023 12:17am Edited Date/Time 3/31/2023 3:58am

Wow another 4 months has gone by… 😭 I finally got everything to button up my top end and have spent many hours swearing at my brakes. Front brake is a mixture of new yz master cylinder old yz caliper that’s now fully rebuilt. Getting the brake line to run through this stupid inside fork guard setup is wrecking my head! Gonna have to get a new old style line made…

turned my attention to the rear brake which is a new pedal, new clevis on old master cylinder… brain hurts 🤯

Drilled and tapped new clevis and did some slicing and filing of the newer style lever to give it clearance 

 

E368226D-C341-4917-B3A4-6226AB4C0FFB

 

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guzziboy532 3/26/2023 12:21am
3/26/2023 12:21am

8BD20A6D-2642-4190-9676-B0232C58BB60.jpeg?VersionId=YKjLkNzlzquxw9JSpent a few hours digging out 7503 rusted staples from 405 previous seat covers and installed SEXY thrill seekers cover.

 

also finally bought some tyres or tires or rubber and swore some more at my bleeding fingers before stepping back to admire my handiwork 

the brand new tank really pops 😜😜😜😜🤤🤤 just need to chuck the plastics on and it’s ready for a firing 🥳

 

EEA40CD8-7227-4BB0-AF39-79DEA662D261

 

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Glen
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Glen 3/26/2023 12:43pm
3/26/2023 12:43pm

love it!

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LOOnatic
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LOOnatic 3/28/2023 1:57pm
3/28/2023 1:57pm

Keep it up Guzzi you definitely have had a battle with this one but seems like your getting close to the glorious first start up.

 

Good move to split the cases now not later

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guzziboy532 3/31/2023 3:57am
3/31/2023 3:57am

Battled a bit more the last few days making stuff fit, finding long lost bits, and not finding some. Couldn’t resist a quick mock up… should be firing this weekend fingers crossed 🤞 

4543D567-1075-4F98-8FFA-BDA5BEB673C8.jpeg?VersionId=vb.O6wBgLO3R8Xc2i91Mbs

 

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Rickyisms 4/1/2023 7:44am
4/1/2023 7:44am

Looks great Guzzi! My Dad’s last race bike was a 1995 YZ250 that he sold to his friend in January of 1996, his friend has maybe ridden it 10 times since then. I saw it a year ago and it’s a straight up time capsule, all original other than tires, air filter, grips, and the those sweet old school levers with the cutouts for your fingers that my dad fitted up way back then (can’t remember the name of them). If he ever lets go of it I plan on snatching it up to display with his number on it. 
 

How is everything down in your part of the world compared to when you first started the build? What weird times those were. 

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guzziboy532 4/4/2023 1:06am
4/4/2023 1:06am

743C00A0-7AA0-4F21-A53A-25C67991D80E.jpeg?VersionId=5RA.xE90qSIb9R6Disaster struck on final tighten of my clutch springs snapped a bolt 🤦‍♀️ 

Had the tig out and was just about to operate and I thought, why not just give it a little “nudge” with a hole punch and see if it moves… hey presto came right out! 😮‍💨 

 

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guzziboy532 4/4/2023 1:08am
4/4/2023 1:08am
Rickyisms wrote:
Looks great Guzzi! My Dad’s last race bike was a 1995 YZ250 that he sold to his friend in January of 1996, his friend has maybe...

Looks great Guzzi! My Dad’s last race bike was a 1995 YZ250 that he sold to his friend in January of 1996, his friend has maybe ridden it 10 times since then. I saw it a year ago and it’s a straight up time capsule, all original other than tires, air filter, grips, and the those sweet old school levers with the cutouts for your fingers that my dad fitted up way back then (can’t remember the name of them). If he ever lets go of it I plan on snatching it up to display with his number on it. 
 

How is everything down in your part of the world compared to when you first started the build? What weird times those were. 

Hey mate it’s gotten better tbh but still takes an eternity to get anything OEM for these old bikes…I am gonna put a set of ARP studs in the pressure plate just need to order them. Not even gonna try get oem 😂😭😜

guzziboy532 4/4/2023 1:11am
4/4/2023 1:11am Edited Date/Time 4/4/2023 1:12am

So put a similar size bolt in the clutch just had to kick this thing over. Some nervous moments and she started second kick!!! 👌👌👌👌👌🥳🥳🥳🥳🥳🥳🥳🥳🥳 could not believe it. Looks like she’s going through all the gears and the clutch seems to be working. Just need to start her a few more times when my neighbours aren’t home and find all the bits I forgot to tighten 😉

 

can’t wait to rip this thing 


 

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