Posts
137
Joined
2/2/2022
Location
Worcester, MA, USA
Hi guys, here again posting yet another turd I've been polishing. Been slacking finishing my 2 other builds (00 cr250& 87 kx125) cause I've been working on a yz project for a close friends thought mine as well post it. He bought this 06 for I think $1600 knowing it needed a frame it had serious cracks down the head tube and since I'm a pack rat and had a bunch of 2016 yz parts including a frame it made sense I'd try to use as much of my newer stuff as possible. Frame, swingarm, rubber mounted triples etc. It started out little rougher then shown, fmf pipe was completely twisted and all plastic was garbage so I spruced it up quickly with plastic I had and he bought a PC works pipe so he could ride it for a bit. 
Before tear down we noticed 2 things riding it. Firstly it was incredibly flat like the power valve wasn't opening. It also felt lean like LH crank seal wasn't seated fully, revs took too long to drop. So then I started tearing down. Throwing enough American bolts out I could build a chevy truck with them 🤣
Onto motor. I pull rh power valve cover and the power valve arm wasn't even hooked up was just sitting there like a limp noodle. With that in mind i still took big power valve cover off and degunked the pv best I could without taking it apart. Can of brake clean later they were moving nice and free. Cylinder off, quick hone and it came right back.
Cases were absolutely disgusting from every possible seal leaking hahaha. Counter shaft, shift shift, kicker, leaky pv cover rubber and no pipe to silencer rubber. This pic was after multiple powerwashing before i yanked it, it was much worse.I'm still not completely done refinishing the cases but I didn't wanna go crazy as the cases are kinda junk and buddy will probably get set of cases at some point anyway.
With the motor out and waiting on parts I decided to rebuild the shock and forks. Shock was a complete pogo stick, almost no oil or nitrogen came out. Forks were more of the same leaving most of its fork oil on the front caliper. Upon disassembly i found broken parts and pieces left and right. Cartidges were mangled and everything was stripped. For less headache i used my 2016 front and rear freshly rebuilt brakes as well as forks. I will tackle these forks with a 03 yz250 build here soon. Heads up, I suck at taking all the before AND after pics and will get better about that in future.
With suspension ready i put the motor together. Buddy wanted a high compression race gas only fire breather so I picked a bud racing head and weisco gp racer elite single ring piston. Checked squish and all was good. New reeds. Rebuilt carb. Cleaned up the porting a little then reassembled
Started to look like a bike again. Lots of new bolts throughout. Cleaned and grease linkage, new drc footpegs springs and pins. Newer ending finding stuff to clean, paint, refinish etc and still lot more to do.
The Shop
DeCal Works Huge Plastic Inventory of UFO and Polisport kits.
Luxon 4-Post Bar Mounts
$189.95 - $239.95
Currently bike is about 95% done but need silly stuff. Ordered plastic kit with no fork guards like a dummy. Carb choke plunger isn't staying up so gotta replace that. Silencer core was broken on the used PC silencer he has so just got welded and gonna go back together. Still teething issues u will get on these kinda builds.
New DID x ring Chain on and plastic on. Acerbis frame guards and protaper clutch perch. Renthal fat bars. New chain blocks, axle nutsWas able to take it for a rip and the snap is back ! Felt very impressive. Also got the universal excel front wheel off and got a whole oem wheel off a 2013 cheap so that helped spruce it up. That excel had shot bearings and spacers were crap. Will be getting him a rear 19in rim and spokes then lacing. So will keep adding pics as it gets closer to the end or if I find more from the build process cause I may have more on my laptop
Finished this thing up month or so back. Pretty happy with it. Silencer core welded and repacked it. Lots of silly stuff replaced. Front brake cable guide, various bolts oem and bolt mc bolt kit, oe rear brake line clips, OE SA caps.tightened up kicker to clevis. Fork guards and hardware. Pipe mounts. More im forgetting. Will probably still do a 19 in rear and probably put a seat cover on. After I replaced the mangled chock plunger thing actually ran worse. After few ohm readings realized stator was dying. New stator installed. Boom runs perfect now. Hope to keep making it better and better for my buddy whos also my boss whos telling me ride it whenever i want so looking foward to dialing it in for him. Havent spent much time on alu yz's so itll be cool
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