1992 YZ250 lockdown-teardown- completed with start up video

sandman768
Profile picture for user sandman768
Posts
6096
Joined
3/21/2014
Location
Saratoga Springs, NY US
sandman768
Edited Date/Time 7/15/2020 1:33pm
Been looking for a 92 YZ for some time now....... found this on Facebook market place...seller may even be a Vital member... looks pretty good from a distance.... figured maybe I could do a quick cleanup of the last owners restore.... after tearing into it, needs full going through...these 92”s are pretty scarce. I feel it warrants a proper restoration. Been going at it pretty hard the last few weeks given we’re all on lock down. Going to keep at it hard until riding/racing starts back up.
Seller was from Kansas, we made arrangements for a friend of his to transport bike down to bike week so I could get the bike. That worked out good, as a I met the guys who brought the bike to PaxTrax Mx on my way to the GNCC is Palatka Florida.
6
|
sandman768
Profile picture for user sandman768
Posts
6096
Joined
3/21/2014
Location
Saratoga Springs, NY US
sandman768 3/31/2020 5:10pm
3/31/2020 5:10pm
Some photos while in Florida... I could not resist tearing into a little just to see how bad it was. The seat/ rear fender/ side plates did not line up at all...as with most poor restores, majority of the hardware was incorrect.



Radiators twisted up pretty good, the grilles are twisted as well, but at least they are there, grilles for these bikes are non existent.
1
sandman768
Profile picture for user sandman768
Posts
6096
Joined
3/21/2014
Location
Saratoga Springs, NY US
sandman768 3/31/2020 5:13pm
3/31/2020 5:13pm
Rear chain guide worn through, but at least it was painted black👍

2
sandman768
Profile picture for user sandman768
Posts
6096
Joined
3/21/2014
Location
Saratoga Springs, NY US
sandman768 3/31/2020 5:17pm
3/31/2020 5:17pm
Reoccurring theme with the black spray paint...
Kinked fuel hose with Ford hose clamps is a bonus...
1
sandman768
Profile picture for user sandman768
Posts
6096
Joined
3/21/2014
Location
Saratoga Springs, NY US
sandman768 3/31/2020 5:19pm
3/31/2020 5:19pm
And... this may have something to do with the seat/rear fender/ side panel fitiment
3

The Shop

See All »
sandman768
Profile picture for user sandman768
Posts
6096
Joined
3/21/2014
Location
Saratoga Springs, NY US
sandman768 3/31/2020 5:24pm
3/31/2020 5:24pm
Rear brake pedal bolt & spring off a Ford F-150. Wrong bolt & spring, pedal did not even move.

10 minutes on eBay I found the correct bolt & spring for 10.00$
1
sandman768
Profile picture for user sandman768
Posts
6096
Joined
3/21/2014
Location
Saratoga Springs, NY US
sandman768 3/31/2020 5:29pm
3/31/2020 5:29pm
Both pipe mounts were broke, but bolts driven through the rubber for custom fit
Triple clamp aluminum spanner nut...... custom pipe wrench edition
2
sandman768
Profile picture for user sandman768
Posts
6096
Joined
3/21/2014
Location
Saratoga Springs, NY US
sandman768 3/31/2020 5:34pm
3/31/2020 5:34pm
Coil is cracked!

Slight leak at petcock... maybe the cardboard & yamabond gasket?
2
sandman768
Profile picture for user sandman768
Posts
6096
Joined
3/21/2014
Location
Saratoga Springs, NY US
sandman768 3/31/2020 5:43pm
3/31/2020 5:43pm
So... full teardown in process....I will just get the chassis sorted, then save the engine for later as I am sure a cylinder replate and crank rebuild are in my future ...
5
sandman768
Profile picture for user sandman768
Posts
6096
Joined
3/21/2014
Location
Saratoga Springs, NY US
sandman768 3/31/2020 5:45pm
3/31/2020 5:45pm
Aluminum parts prepped for Vapor blasting....
2
sandman768
Profile picture for user sandman768
Posts
6096
Joined
3/21/2014
Location
Saratoga Springs, NY US
sandman768 3/31/2020 5:52pm
3/31/2020 5:52pm
Did test fit my new PC pipe & silencer before teardown. Pipe fits good, silencer rear mount bolt hole is off by about 5mm”s, that is due to the rear frame section welded on about 5mm”s too far back! I will use the silencer as a jig to reweld the rear rail back on.


4
Chance1216
Profile picture for user Chance1216
Posts
5304
Joined
4/1/2018
Location
Federal Way, WA US
Chance1216 3/31/2020 8:20pm
3/31/2020 8:20pm
I’m ready to watch you work your magic. I loved those year bikes.
1
sandman768
Profile picture for user sandman768
Posts
6096
Joined
3/21/2014
Location
Saratoga Springs, NY US
sandman768 4/1/2020 5:51am
4/1/2020 5:51am
Chance1216 wrote:
I’m ready to watch you work your magic. I loved those year bikes.
Thanks Chance1216, I already have a bunch of NOS parts. Going to go very close to original on this build.
3
Chawnz
Profile picture for user Chawnz
Posts
7
Joined
12/27/2015
Location
GB
Chawnz 4/1/2020 12:32pm
4/1/2020 12:32pm
Ah I saw your bike on Facebook, I'm also doing a 92 250 so will follow this thread.
sandman768
Profile picture for user sandman768
Posts
6096
Joined
3/21/2014
Location
Saratoga Springs, NY US
sandman768 4/1/2020 3:51pm
4/1/2020 3:51pm
bonseff wrote:
Nice get!
These bikes are hard to find for some reason, I got tired of waiting... It has some good points but my OCD has kicked into overdrive already....
1
sandman768
Profile picture for user sandman768
Posts
6096
Joined
3/21/2014
Location
Saratoga Springs, NY US
sandman768 4/1/2020 3:52pm
4/1/2020 3:52pm
Chawnz wrote:
Ah I saw your bike on Facebook, I'm also doing a 92 250 so will follow this thread.
Thought about doing this on Facebook, but I like this platform better. I”m fairly new to face book ... still not sure how it all works😂
sandman768
Profile picture for user sandman768
Posts
6096
Joined
3/21/2014
Location
Saratoga Springs, NY US
sandman768 4/1/2020 3:55pm
4/1/2020 3:55pm
The 91-92 radiator grilles are NLA and very hard to come by. I had heard the 93 grilles may fit. The 93 grilles are still available from Yamaha.... we can put that theory to rest now.... not even close...


Pit Row

See All »
sandman768
Profile picture for user sandman768
Posts
6096
Joined
3/21/2014
Location
Saratoga Springs, NY US
sandman768 4/1/2020 4:03pm
4/1/2020 4:03pm
Radiators were twisted up & rt side has a good sized impact. Thought about buying the Chinese units but....with all this shit going on right now.... I feel better spending within the USA. I sent the radiators to Brett at ICW, I will post the repaired coolers when they return.


3
sandman768
Profile picture for user sandman768
Posts
6096
Joined
3/21/2014
Location
Saratoga Springs, NY US
sandman768 4/1/2020 4:07pm
4/1/2020 4:07pm
Clutch pull was way to hard... cable routed wrong and these levers not bringing anything to the party
sandman768
Profile picture for user sandman768
Posts
6096
Joined
3/21/2014
Location
Saratoga Springs, NY US
sandman768 4/2/2020 5:35pm
4/2/2020 5:35pm
This took a lot longer that it should have....




Silencer now fits, along with plastics & seat. Will fine tune plastic fit upon final assembly. Cool design with plastics all integrated with rear frame rails, but one loop out and nothing ever fits right again! Replaceable rear subframes...great idea👍
5
Chance1216
Profile picture for user Chance1216
Posts
5304
Joined
4/1/2018
Location
Federal Way, WA US
Chance1216 4/2/2020 9:20pm
4/2/2020 9:20pm
I liked the hand grab at the rear side panel. The little things like that made life easier.
1
sandman768
Profile picture for user sandman768
Posts
6096
Joined
3/21/2014
Location
Saratoga Springs, NY US
sandman768 4/3/2020 5:21am
4/3/2020 5:21am
Chance1216 wrote:
I liked the hand grab at the rear side panel. The little things like that made life easier.
At some point someone did some repairs to the rear rails...very poorly I might add....My brother & I had to cut them off, tack them on, then bolt up all the parts, seat, rear fender, side panels & silencer to test fit for alignment...we must have done this about 10 times before we got everything right! ... while we were at it, we removed off all the stripped out welded frame nuts and welded on new nuts. It was a pain in the ass.... No stripped out frame nuts on my bikes....the frame had been powder coated over all these frame issues... I think I can spot refinish the frame to match pretty good.
1
Bent206
Profile picture for user Bent206
Posts
133
Joined
10/1/2016
Location
Coventry, RI US
Bent206 4/3/2020 5:35am
4/3/2020 5:35am
I'm a fan of your bike builds.
One of my favorite bikes from that era. The oem color combo screams early 90's!

It is very rewarding bringing these old bikes back. Fixing everyone else's "fix" and doing it the right way. Keep up the good work.
2
Bent206
Profile picture for user Bent206
Posts
133
Joined
10/1/2016
Location
Coventry, RI US
Bent206 4/3/2020 7:19am
4/3/2020 7:19am
sandman768 wrote:
So... full teardown in process....I will just get the chassis sorted, then save the engine for later as I am sure a cylinder replate and crank...
So... full teardown in process....I will just get the chassis sorted, then save the engine for later as I am sure a cylinder replate and crank rebuild are in my future ...
What year YZ frame is in the background?
Spare parts for this bike or another build?
sandman768
Profile picture for user sandman768
Posts
6096
Joined
3/21/2014
Location
Saratoga Springs, NY US
sandman768 4/3/2020 10:07am
4/3/2020 10:07am
Bent206 wrote:
What year YZ frame is in the background?
Spare parts for this bike or another build?
It’s a 94 Honda Cr250 frame...just happened to be a good place to set the YZ tank at the moment....The YZ jumped in front of the CR in the restore line. I”m slowly gathering parts for the CR, it was all original but not a low hr bike, needs complete redo. But all the major stuff is there and usable. Every time I say I”m done building bikes, I buy another one... I have a problem for sure.... must stop buying bikes....😂
6
yak651
Profile picture for user yak651
Posts
6705
Joined
8/26/2006
Location
Appleton, WI US
Fantasy
192nd
yak651 4/3/2020 11:45am
4/3/2020 11:45am
At least you have a sense of humor and can laugh about it...and you got some new plastic with the "restore"!
Look forward to seeing the finished product.
sandman768
Profile picture for user sandman768
Posts
6096
Joined
3/21/2014
Location
Saratoga Springs, NY US
sandman768 4/3/2020 3:28pm
4/3/2020 3:28pm
yak651 wrote:
At least you have a sense of humor and can laugh about it...and you got some new plastic with the "restore"! Look forward to seeing the...
At least you have a sense of humor and can laugh about it...and you got some new plastic with the "restore"!
Look forward to seeing the finished product.
I have bought some really clean bikes and some really hammered bikes, this one falls somewhere in between... this is the first bike I bought that was supposedly rebuilt or restored. I knew from day one I would be framing this bike. All good, I enjoy building them. All the little surprises just make it more of a challenge. I was told the cylinder is stock and the stock crank was still good👌.... I”m curious to see what’s inside the engine... I did look up the exhaust port and was not surprised to see a Namura piston!
1

Post a reply to: 1992 YZ250 lockdown-teardown- completed with start up video