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wilh72
4/21/2020 11:47am
4/21/2020 11:47am
Edited Date/Time
4/24/2020 8:31pm
So I picked up this 96 YZ250 a few days ago, Haven’t dug much into it yet but was wondering if Its missing something? I’ve never seen a reed block that looks like this. Then again I’ve never owned a 96 YZ250, I’m Getting together a parts list. I looked up a diagram online but I don’t think it’s for the 96. Thanks
The Shop
I built a '95 and had some of those same questions. My build is here, maybe some useful info.
https://www.vitalmx.com/forums/Bike-Builds,46/1995-YZ-250-No-frills-no-…
Yeah, the Boyesen Rad Valve is good. Check those reeds, though!
I tried to use the original carb and that was a mistake. Spent some money on o-rings and such and
could NOT get it to run right. What I finally realized is that the orfice the needle slides into, which is not replaceable, was worn. Apparently somewhat common on older bikes with grit getting in there. If that happens, you will never, ever get it jetted right. I ended up getting a new KEIHIN 38mm PWK AIRSTRYKER w/Jet Kit from JD Jetting. Came with his jet kit. Played with the jetting some and ended up back at his recommended baseline settings. Works awesome and probably the best bang for the buck. Wish I would have done that from the get-go as it would have saved ton of time and really wasn't that expensive considering the time and cost of gaskets trying to do the original carb. https://jdjetting.com/product/jdkh08-keihin-38mm-pwk-airstryker-w-jet-k…
Forks . . . Yamaha uses the same steering head bearings from at least '95 to '08 or so. I swapped on a set from '07. Straight fugging bolt on. Couldn't believe it. There are, I'm told, a few different stem lengths but I got lucky. Mine is a little mix and match with a different year front wheel which caused some axle headache. Looking back, try to get the wheel/axle/brake, forks and clamps all from the same bike. If the stem length is correct, you're good. You might have to fiddle with the steering stops. I relocated mine to the frame. The shock from later models will also work. Again, double check length as I might have gotten really lucky.
'05 and up forks are SSS and more expensive. Pre -'05 are plentiful and cheap. But try to buy local, take your frame and double check the fit.
Something to watch- the rear wheel spacers are *slightly* different lengths. Make sure you have them correct. Sounds silly but you see rear brake calipers with rotor gouges all the time on those bikes from people getting it wrong.
Good luck!
Hold off on your front wheel until you figure out your fork situation.
If you are going to get your frame painted or powder coated, take a look at
a later model rear brake master cylinder that doesn't use that goofy remote reservoir.
Straight bolt on. (See my thread) Then you can grind off those little hose hooks for a cleaner look. Also
hold off on painting the frame until you figure out the forks what with possibly relocating the steering stop.
Also, those bikes are pretty notorious for needing good gas. Plan on running
at least race gas mixed with pump 50/50.
If this is your first build, if I could offer some advice as that '95 was my first big rescue project.
Get a notebook and keep lots of notes. Every night when I left the garage, I would make notes of what I had done
and what needed to do next. Because it was so frustrating starting to work and going "Aw shit, forgot to get that one allen bolt from Ace Hardware!"
Get a decent Vernier caliper. Makes things a lot easier. When buying from eBay, try to get really detailed photos and measurements from the seller. I bought lots of wrong stuff, and wasted lots of time, not being more effecient.
I worked on the chassis first and stuck the motor away till I was fully done with the chassis. Otherwise I had too many different loose ends and parts lists and it was easy to loose track. Granted, I was not on a time frame. Do the motor yourself. It's really not that hard and immensely satisfying. Use OEM bearings. Have fun and good luck!
It will come in so handy. I picked up good, used one on eBay for about $40.00. Money well spent.
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