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On the update front I have been a little lax on the progress of this build as a whole lately, I am 7 days away from being married so I have been a little occupied doing wedding things. But once I'm back on deck from the honey moon and get my WR450F supermoto back on the road I will aim laser like focus on this YZ.
Just last weekend I cerakoted the cases along with a few ancillary pieces so that is a large task off the list, all that is really remaining for me before I will start reassembly is:
- Skim hubs and cerakote.
- Hone cylinder.
- Get the head cut and cerakote.
- repair CDI plug receptacle.
- Polish gearbox.
- Build wheels
- Build forks, very keen to get the forks sorted as I Have factory KYB DLC tubes on their way for them.
- Blast & paint frame, If anyone has the original paint code for the Yamaha metallic blue please share so I can save a few trips to the paint shop for them to get it right...
Basically I have 95% of the parts I need to smash this thing out but the below is what I can think of off the top of my head.
- 280mm front disc.
- wheel bearings & seals
- linkage bearing kit
- Graphics & seat cover, really keen on the 2004 Factory Yamaha look.
- Motion Pro throttle assy.
- Clutch cable
- Brake lines
- Piston, will be a Wiseco or a Wossner
- ODI lock on grips
- Hopefully a 1744 carbon silencer. (check out his Instagram @1744_racecreations)
- Steering stem bearings.
That titanium cone pipe Adami Alexi builds is pure 🔥 fire 🔥
Any way, I thought I had more progress pics but basically where it stands is I have the Case halves together with the brand new crank, polished gearbox assembly and all new bearings. The frame still hasnt been painted and the forkes havent been built yet either but its primed and ready for a few large leaps of progress in the coming weeks.
I thought this jig would have helped a lot more than it did but I reckon I spent more time setting it up in the thing than what I would have saved just doing it normal, I guess if you are doing lots of them it would pay off.
I am hoping forks will be built in the next two weeks or so, then Ive gotta attack my list of things to do.
Also if anyone has the Yamaha metallic blue paint code for these bikes please share.
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Yep the graphics kit will be a just like the 04 model except for logo changes. My thoughts also haha.
Yeah I wont be going that way on this build but I do have him working on somthing else for me thats not for this bike but waaay cooler.
I got the cylinder cleaned up and assembled with a refurbished powervalve assembly and coated the cylinder head. The top end should be all done and finished also but oi ordered the wrong piston after too many beers so now i am waiting for the correct one. But I did a mock up anyway to see how it will look.
Got a heap to do before my dead line of the end of this month. Still have to coat the hubs and build the wheels, paint the frame, and assemble the whole bike. Suspension will be finished this week and i should have pretty much all remaining bits here by the end of next week aside from the graphics and seat cover which I am yet to order. I really wanted a Thrill Seeker seat cover as I think they are the best out of the dozens I have fitted but a 4 week lead to down under puts them out. It will be nothing fancy just blue and black stock look so even a new stock one will be fine, lets see what I can find at short notice...
Two weekends ago I painted the frame, I used a two pack mono chrome paint over a good etch primer. I originally wanted the paint to be matched to the original, but I had it mixed a little different to match the plastics better, more blue and less purple. I am very happy with how it turned out.
So as it sits now I have this weekend to get this bike ready... I am looking to get the front wheel redone, tyres on and wheels in, I am waiting for the correct rear brake line as I ordered one to suit 2002 instead of the 2009 rear end fitted, then the brakes can be bled and sorted. I have the last bit of titanium on its way, my estimate is that this bike is around 70% titanium. I didnt go Titanium axles, linkage bolts and the few select internal engine bolts or disc and sprocket bolts but most of it is Ti. Where I could I went with Stainless flanged nuts and I even found flanged aluminium nuts with stainless thread insert which I thought were very cool, mainly because they were super expensive for a nut...
The brakes should be rather impressive. Big 11mm master cylinder and a 280mm disc for the front, 2009 set up to match the swing arm on the back. I couldnt get a new Motostuff 280mm disc because off local supply and the time frame I have to get this thing going, but lucky the local bike shop had one off an older race bike from a few years ago they were willing to sell me for cheap, a quick clean and its as good as new except from what looks like a few failed attempts to remove broken disc bolts...
Nice 3D printed rear brake line guides to replace the failed attempt of dyeing the originals.
I've mounted the 2002 plastics to the 2014 front end nicely with a little bracket fabbed up to mount the front number plate to the triple clamp, I really like the older shape. The engine starts and idles well after a little stuff around with the timing. Its all looking very sexual and I'm hoping it all kind of falls into place and I don't have any more set backs or beer fuelled oversights... This is how its looking in my shed now with all brand new genuine Yamaha plastics and Guts seat cover in original colours.
BUT, you need some BDP/other fancy axle blocks
Is there a link to the “ K-tech teflon sliders ” as I haven’t seen those?
Thanks
I random;y entered years and models but its much the same, Ktech make unreal stuff.
Pit Row
They were the only ones making axle blocks for the older bikes, but now I see you have the updated swing arm.
They still have you covered 🤙
I didn't read every word, so I'm not sure if you addressed this, but I thought I'd point out that the late model YZ250F and YZ450F forks are about 10mm longer than the most common two stroke forks in standard trim.
The difference is in the cartridge assembly, but the actual cartridge tube is the same length. If you've already dealt with it, good deal and keep up the awesome work!
Did you ever get this thing buttoned up?
Looking mint, just been through it all can’t wait to see the final thing. What brand is the stand you have got? Looking for one similar - is it genuine Yamaha? Cheers!
Sorry to all those that were following this build, I did get this thing done and a few years ago too! I pushed hard to get it done and ready for a Moto Holiday down in south east Queensland riding some cool tracks but it gave me no end of grief for 3 days straight! First it was so lean it ping'd its head off, so i made it richer then it was so rich it made no power and felt like a rag was in the air box, i adjusted the metering rod the power jet the float height, ignition timing, you name it I did! it was all over the place and it was so frustrating I eventually gave up on it and rode my mates KTM450 and Yz125's for the rest of the trip and left the 250 at our base camp just so I could at least enjoy a lap after the 11hour car drive down. When we got back i put it under a blanket for nearly two years without touching it, to be fair we had our first child in that time also...
In my haste to get it going for our deadline I Missed a major issue with the CDI, you will see on the first page of this thread the CDI plug in the harness had short circuited and blown out the side, well for whatever reason some how I did not think to suspect that the CDI might have been damaged as a result and could be culprit. Anyway it was, and instead of replacing just the harness I should have shouted it a new CDI at the same time. A good second hand one and she's back up and running better than ever, still need a little bit of tuning to get rid of the lean pipe bang on decel, but that's to be expected as I have the adjustment so far out on the Lectron I need to rip it out, give it a full clean and get it back to the base setting it came with.
Finished Pics
The hubs are drool-worthy. Fantastic job!
Looks shit, too much bling, way overdone.
WTF is even ZOO?
Are we looking at the same bike?
Post a reply to: #mid2k YZ250 FINISHED