1994 YZ250

Yz229
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2/25/2022 8:35am Edited Date/Time 11/21/2022 11:46pm
I wasn't going to do a project build since I'm still low on funds after the crazy YZ315 build I did and now a 2020 YZ450F...but here we are.

Found a rough, blown up 94 YZ250 on OfferUp back in August for $600. For some reason, I always loved the very 90's look of the 93-95 YZ's and had to have it! Was just going to get it running and just have it around for my friends and family to ride. Basically a bike they can thrash and not feel bad about it.

Problem is, I can't leave things alone. I have to wrench of something at all times...

So now here we are. I was just getting the bike looking fresh, greasing the bearings, new steering stem bearings and what do I find on eBay? There it is, a DeVol linkage! That's all it takes for me to want to start a new project. One little part that's somewhat rare to start a build. I guess it's time to start building.

Not 100% sure which direction I want to go with this build yet. Was thinking either a more hardcore WR style build with stronger (Tom Morgan porting), smoother power, re-valved, re-sprung stock suspension to go with it. Thinking almost like a modern YZ450FX feel. But with that, it will look like an old YZ replica. Almost something you could race the Glen Helen 24hr race. (Yeah, I saw RMATV do this but I had that idea before they even did it)

Or I can go the route of an actual replica which plenty have done. Hard hitting, stiffer suspension. Still undecided since I'm still browsing the web hoping to find some parts. Plenty of people have done this. I was thinking of doing a long rod engine, but Tom Morgan talked me out of it...although it would be very cool.

I will be powder coating the frame with the OG dark blue metallic paint. Will also want to vapor blast the engine, swingarm, etc.

Some other parts I am looking for.

-Works pipe
-Ti Subframe
-Blue plastic shrouds (Only white and black for sale new)
-Frame guards (DeVol I believe?)
-Radvalve








5
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Yz229
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2/25/2022 8:40am
Top end was rough. Definitely too lean. easy enough just to clean up and throw in new piston and rings. Surprisingly, bottom end felt pretty good.

Jetting was 40 pilot, stock needle 2nd position, and 350 main. A/S was out far enough to cause a lean bog. Way too lean of jetting, especially trying to ride it in the desert with a paddle.

I threw in a 45 pilot, and 390 main. Runs really well with this old Mikuni carb. I see no reason to swap to Keihin at this time.





2
Yz229
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2/25/2022 8:42am Edited Date/Time 2/25/2022 8:46am
Threw on some new plastics for now and graphics from Evo-MX (this was before I decided I was going to build it.) I skipped doing shroud graphics for now since I am looking for new, or like new blue shrouds.

Also waiting on seat cover. Will be going with the same one, but I want to go with new foam and possible the grippy version from Evo-MX

I went with the number "823" for now since that is my wife's birthday. Have to make her happy!






5
Yz229
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2/25/2022 8:51am Edited Date/Time 2/25/2022 9:07am
Took it to Pala one day to see how it was. Not great to be honest. The bar bend was horrible, with an insane amount of sweep. Grips were terrible (blue grips in previous pictures). Very slippery. The deep pocket in the seat. Even with earlier YZ's had a flatter seat profile. The 93-95 were very odd with the steep section going up to the tank. Very hard to stay forward especially with the slippery non-gripper seat. Will be ordering the "Hi-Grip" option seat cover from Evo-MX.

Funny thing is, it was very easy to ride. Very comfortable and didn't tire me out even sliding all over the bike. Power was plenty as well.

With some new bars, grips, seat cover, porting, foot pegs, tires and suspension re-valve, I think it will be an easy bike to ride fast.

When I got home I swapped to much more modern Pro Taper Evo SX bend with better grips. Haven't ridden with them yet.



4
Yz229
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2/25/2022 8:53am
Stock foot pegs were rough as well. Ended up grinding the stock pegs up from my 2020 YZ450F and putting them on. Feels much better at least on the stand.


6

The Shop

Yz229
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2/25/2022 8:56am
And finally, the part that swayed me to want to tear down the whole bike and basically start a fresh build.


8
Kidkawie
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ქუთაისი GE
2/25/2022 1:01pm
Cool build!
1
Yz229
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2/26/2022 7:55am
Kidkawie wrote:
Cool build!
Thank you!
2/27/2022 7:22am
You can put later year suspension on it like year shock up to like 04. The sss front end can be put on but you have to redo the metal steering stop tab on the frame as in cut it off and reweld a new one on.

Rear integrated rear brake master cylinder will fit as well.
1
Yz229
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2/28/2022 11:51pm
I even had SSS suspension that was setup for Enzo for my RBSR bike but I sold it all awhile back. I think I'm going to keep it as period correct as possible with stock suspension.

Maybe in the future I will try SSS if I can find it cheap.

Good idea on the rear integrated. I will try to find a cheap one on ebay
Yz229
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3/1/2022 7:31am
For those that have used the devol linkage, what bolt did you use for the lower rear shock? Stock 94 is too short and is supposed to thread into the linkage. I tried the bolt and nut from my newer Yamahas and it seems to work ok, but the linkage doesn't have a place to hold the "half moon" head.


Yz229
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San Diego, CA US
7/11/2022 11:07am
Decided to get a new PWK Airstriker.

Bolts right up with no issues. Anyone have a good starting point for jetting? I threw in 172 main, N3EW 2nd pos and 50 Pilot. It was very hard to start, plug immediately got oily due to being too rich on the bottom. A/S didn't really make a difference, so ordered a 42 and 45 pilot to try out.
1
Dave #125
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Andrews Farm , SA AU
9/14/2022 2:09pm
Yz229 wrote:
Stock foot pegs were rough as well. Ended up grinding the stock pegs up from my 2020 YZ450F and putting them on. Feels much better at...
Stock foot pegs were rough as well. Ended up grinding the stock pegs up from my 2020 YZ450F and putting them on. Feels much better at least on the stand.


What did u need to grind off to get them to work?
I have a set of 2020 pegs sitting there for my 1994..
Cheers
Yz229
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378
Joined
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San Diego, CA US
9/17/2022 10:32pm
Yz229 wrote:
Stock foot pegs were rough as well. Ended up grinding the stock pegs up from my 2020 YZ450F and putting them on. Feels much better at...
Stock foot pegs were rough as well. Ended up grinding the stock pegs up from my 2020 YZ450F and putting them on. Feels much better at least on the stand.


Dave #125 wrote:
What did u need to grind off to get them to work?
I have a set of 2020 pegs sitting there for my 1994..
Cheers
You need the mounting area to be thinner on the newer footpegs. If you compare the old vs new side by side you will see what I mean. I just used an angle grinder.
1
Yz229
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9/17/2022 10:35pm Edited Date/Time 11/21/2022 11:46pm
Forgot to post, got PWK running great! NECJ needle and 45 pilot was key. Also, got a new seat cover a couple months back.
4
Rickyisms
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FL US
9/18/2022 7:23am
Were you able to figure out the linkage set up?
Yz229
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San Diego, CA US
9/18/2022 9:12pm
Rickyisms wrote:
Were you able to figure out the linkage set up?
Yes, I ended up using the lower linkage bolt from my 06 YZ250. The linkage doesn't have the notch to prevent it from spinning, but it seems to work.
1

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