|
Post by jaxmoto on Jan 26, 2013 14:30:51 GMT -5
Hey everyone, Jaxmoto is starting a new off road motorcycle project and I thought it might be fun and maybe even educational for the club to follow along. I'm not thinking too fancy, just some posts and pics of the process as it goes along. The process is going to take a few weeks between parts orders and actually finding the time to work on my own bike but I will do my best to keep the posts current. I'm not much of a writer so please bare with my horrific spelling and poor grammar. Also, feel free to ask any questions or make any comments on the project as it progresses.
Goal: To refurbish and convert a non-current motocross style bike into a competitive off road racer for a reasonable amount of money. (less than $3000.00 total cost) Even though this has been common practice over the years, I never had much interest in doing a project like this. I would much prefer to buy something proven on the trails, throw a set of bark busters on it and go. These days it is not an any easy thing to do without spending in excess of 5 -7 thousand dollars. More if you're purchasing new. This project has come about after a long hard look at my options to get back on the trails. With a new growing business that still has a long way to becoming stable, I thought it a little irresponsible to spend or even borrow that much money on something with no financial return. On a more personal note, I’m really tired of not riding. It's like working in a candy store and being on a diet. The lack of exercise, the ability to“blow off some steam”, and the lack of friendly interaction with other riders has all taken its toll. It's time to ride again. So here we go, enjoy!
Bike: Our donor bike for this project is a 2000 model Yamaha YZ250. I know some of you are already cringing but bare with me. The bike was found on Craigslist in Elkton, Florida on a potato farm. For the past 5 years, it was used to tote tools and parts back and forth to broken John Deere tractors in the field. No, I'm not kidding. The farm was almost 5000 acres and the young guys working the crops found this the most inspiring way to cross that much land performing errands. After some friendly negotiations and a two hour ride, I owned it for the small sum of $800.00. Overall, the bike doesn't show many hard hours. A set of tires, some tuning, and some minor repairs would bring the bike back to useable. The motor runs and the wheels turn but its ugly. The major expense comes with trying to make this thing trail friendly. Everyone who has ever rode one of these bikes knows how violent they can be with power delivery. The suspension is also dated, valved and sprung for motocross. Not good. The initial parts “wish list” is completed and already has to be downsized to stay in budget. Currently we have the following parts on the way: 13 ounce stealthy flywheel weight JD jet kit FMF Gnarly pipe and turbine core II spark arrestor IMS 3.0 gallon tank Gold Valves front and rear/ springs front and rear Renthal enduro fat bars and adapters Talon sprockets and oring chain numerous wheel and suspension bearings and seals new plastics air filter, grips, levers, brake pads, cables and other top secret upgrades We have taken some pics of the bike before any work and would like to post pics on all the repairs as we go. For now we wait on parts. Later, Don
|
|
|
Post by bmiller on Jan 26, 2013 15:39:45 GMT -5
Popcorn is in the microwave, and I'm ready to watch....
Sounds fun.
|
|
|
Post by ssummey on Jan 26, 2013 18:36:47 GMT -5
Don, Interesting build since I have acquired a 2002 YZ250 and have been contemplating after a half dozen rides to keep or sell it. Build on, i'll be watching to.
Scott Summey
|
|
|
Post by jaxmoto on Jan 26, 2013 21:56:48 GMT -5
A little more info as to why we picked this model: In 1999 Yamaha built the two stroke engine that changed the 250 class. Every design and model since, has been based on this engine. Horsepower took a back seat. Smooth power delivery became the goal. Randy Hawkins won everything (Including the SIX DAYS) with this engine. It is one of the most reliable two-strokes ever built. Not that I have to worry about the SIX DAYS but.....Just saying.
|
|
|
Post by jaxmoto on Jan 29, 2013 12:58:16 GMT -5
Donor bike Attachments:
|
|
|
Post by jaxmoto on Jan 29, 2013 13:07:13 GMT -5
Just for kicks, I bolted on the flywheel weight that came today and took a little advance out of the ignition timing. Unreal!! Everyone said go with the 7 or 9 oz. weight but I just couldn't believe that would be enough to tame this beast. I put a 13oz on and can't be happier. The low end is huge and the power hit is probrably half as violent. Awesome first mod!
|
|
|
Post by jaxmoto on Jan 29, 2013 13:08:14 GMT -5
13oz weight install with the timing backed off. Attachments:
|
|
|
Post by jaxmoto on Jan 31, 2013 12:45:48 GMT -5
Parts starting to roll in for the YZ.
|
|
|
Post by jaxmoto on Jan 31, 2013 12:47:38 GMT -5
Still waiting on a few key items. Planning to start disassembly Monday. Attachments:
|
|
|
Post by bmiller on Feb 10, 2013 17:34:22 GMT -5
How's the build coming? Any rides yet?
|
|
|
Post by jaxmoto on Feb 12, 2013 15:08:56 GMT -5
We've made some progress with the build but as we all know, these old bikes can be full of surprises. Currently, i've managed to finish rebuilding all suspension linkage and swingarm(extremely messy and difficult), most bearings resembled rusty dust and needed to be cut out. New brakes, wheel bearings, jet kit, sprockets, and other misc parts have been installed. Sent the shock over to Doug Harvey Racing for the revalve. Waiting on a few things but slowly coming along. Attachments:
|
|
|
Post by jaxmoto on Feb 12, 2013 16:16:37 GMT -5
Here's a couple pics of the olld and new parts. Note: anyone doing one of these linkage and swingarm rebuilds, I recommend OEM parts but the "ALL BALLS" bearing kits are not too bad. They are usually all inclusive on these types of repairs but the actual quality of the metals is not the same as OEM. Most of the aftermarket stuff like this is make by China man but is round about half the cost of OEM. Lastly, these types of repairs require planning and the correct tools. Big hammers, punches, the "correct" bearing and seal drivers and sometimes a torch and cutoff wheel (dremel).
|
|
|
Post by jaxmoto on Feb 12, 2013 16:17:53 GMT -5
Attachments:
|
|
|
Post by jaxmoto on Feb 12, 2013 16:18:47 GMT -5
Attachments:
|
|
|
Post by jaxmoto on Feb 12, 2013 16:19:24 GMT -5
Attachments:
|
|
|
Post by jaxmoto on Feb 13, 2013 10:58:52 GMT -5
Almost ready to ride. lol. Poor old YZ. Attachments:
|
|
|
Post by bmiller on Feb 13, 2013 18:23:22 GMT -5
yeah looks like they were due for replacement. ;D
|
|
|
Post by queenofslow on Feb 13, 2013 21:01:54 GMT -5
I do not understand.... where is the bike, Don?? where did it go
|
|
|
Post by jaxmoto on Feb 20, 2013 12:34:33 GMT -5
We've made some real progress with the YZ this week even with some of the unforseen problems. With any luck at all, it will get its first test this weekend. As of right now, we're waiting on the fork revalve from Doug Harvey and some steering bearings. Here's what it looks like now. (Wednesday 2/20). Attachments:
|
|
|
Post by jaxmoto on Feb 20, 2013 12:54:56 GMT -5
Here is the list of all the repairs and mods and a couple last pics before the finished unit. If anyone is interested in actual pricing of these parts or time involved with installation, just ask and I will post. A few items were given to me and some bought used. If it was all new and retail, I'm pretty sure we would have gone over our $3000.00 limit. As of now, we're still in budget. Yay! 13 oz. flywheel weight FMF Gnarly pipe and Turbine 2 spark arrestor Pro Circut top and bottom triple clamp ( Reduces steering rake for woods riding) Dunlop Geomax 100/90 21 MC31 frt. tire, heavy duty tube and new rim lock Dunlop Geomax 110/80 19 MC51 rear tire (low profile to simulate 18" wheel typical of woods bikes) heavy tube and new rim locks Boyesen high volume water pump and clutch cover (keep cool at low speed) Hinson inner and outer cluch basket with OEM cluch plates James Dean jet kit (Best slide needles i have ever worked with) IMS 3.0 gallon tank and all new Acerbes plastics G2 throttle (slows down carb slide actuation for more tamable power delivery) Renthal sprockets and DID o-ring chain (stock gearing for now) Front and rear EBC MX brake pads Race tec springs frt and rear for a 200 lb rider frt and rear suspension revalve by Doug Harvey Replacement of every bearing on the chassis (All Balls Kits) Renthal CR High bend aluminum bars Gripper seat cover levers, cables,master cyl rebuild kits, Uni air filter, new hardware, etc.
|
|