1982 YZ250 project

[JustInMass]

the updates are fun to read too

keep up the good work!

Ditto that - it's like reading a thriller novel

[Paul_E_D]

Lol!

[BMFR6]

Nice! That is the best feeling. It's just... Aaaaah!

lol. well, i don't know about Aaaaah. The bike is 27 years old so it may be more like Aaah, ehh.

[JustInMass]

trying to be patient...

[BMFR6]

Okay, time to put up some pics..... I'll try to narrate as best as possible, but its been a long weekend. This first post is prior to a "lot" of cleaning of various parts.

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[BMFR6]

Here are the case halves after cleaning. the pic makes them look a bit rusty still, but that is actually black paint. yes its from the factory, i didn't paint it. The third pic is of the assembled bottom end. this was just a test fit as in my excitement i botched a crank seal and would rather replace it now.

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[BMFR6]

Okay, the first pic is of a drain valve in the airbox.... and what came out of it. Next is what you don't want your swing arm bearings and bushings to come out like. Then the fixed linkage, the pic naturally doesn't show you how well it moves. Finally the swing arm bearing/busing job is 99% complete. i am waiting on one more shim, probably could have picked it up at home depot.... but the one that was in the bike came out in about four pieces.
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[BMFR6]

Speaking of the airbox...... a new filter is on the parts list.

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[BMFR6]

And, this is where it stands tonight..... getting there. frame and number plates painted. I actually installed the airbox as well, but the pics are before that of course.

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[TheIglu]

Lookin good!

[breakdirt916]

sweet! they look brand new

I want to beat up my xr80 just so I can fix it up

[BMFR6]

Lookin good!

getting there anyways. one step at a time.

[Paul_E_D]

NICE! That thing is going to look good, and ride even better. I can't wait to see it go. I'll bring my earplugs!

[BMFR6]

Well, I'll hopefully get the forks filled and installed tonight. Looking for some insight and doing my best not to bombard PK with pm's, nobody likes to work for free.
The Clymers manual covers how much oil for the forks for every model except mine (YZ250J) and unfortunately every model is different. I tried to find some info online and the best source I found was a magazine artice from 1982! This is what they said regarding how much 15 wt oil to put in, "measured to 6" from the top of the tubes with the springs removed and forks collapsed."

Now they recommend the same weight oil PK did, so thats good, but this isn't the most scientific approach. You guys think this is a realistic approach?

[Paul_E_D]

6" from the top maybe. That would be in the ballpark, if a little low by today's standards...

[BMFR6]

Then regarding the rear shock.... not sure whats going to happen there. The manual states the service is limited to spring changes, removal and replacement. I don't think there is much that can be done with it. I'm not even positive there is nitrogen in the compression resevoir and of course a) I'm not going to play with nitrogen anyways b) there is no standard fill valve.

i did take the spring off so I can clean a bit more thoroughly, there is resistance when compressing/extending the damper, so thats a good sign. good times.

[BMFR6]

6" from the top maybe. That would be in the ballpark, if a little low by today's standards...

okay, well thats a good starting point then. thanks.

[BMFR6]

So...... would this be considered progress??

3/8/09
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4/9/09
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It has actually taken longer than I had hoped, but it also looks better than I planned. Waiting on some parts has caused slight delays, and well you know, idle hands....

[BMFR6]

Few more pics. She's come a long way, still a bit to go but the end is in sight. With the exception of the wheels and the swing arm, everything is torqued down. I'm sure the wheels will be back and fourth 50 times between now and completion.... but working on the bare frame gets old, it's a damn balancing act so I threw the wheels on to weigh things down a bit. The rear shock will be going in soon but I ordered a new "stopper" given the fact the old one crumbled when I touched it. Will be adding some new (used, but better than what was on there) fork boots as the dust seals on these forks couldn't block a sneeze at medium range. Few other tricks up my sleeve to make it look nicer as I add things back on, glad I bought plenty of spray paint.

And just to point out, check out that rear tire, weather forecast for 6/20/09..... sand storm!

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[butcher bergs]

Gotta say, that thing is really starting to come together!

[BMFR6]

Lastly... I will be placing what should be the "final" parts order tomorrow. Fingers crossed I haven't missed anything else.

And Paul, all the new bits in the linkage.... Aaahhhhhhhh, like buttah!!! I can pick the rear wheel up to the frame and let it down multiple times and the frame doesn't even wiggle on the stand. It may not be the best shock in the world, but I'm giving it a fighting chance.

[BMFR6]

Gotta say, that thing is really starting to come together!

little by little anyways.

[JustInMass]

Looking good dude!

[McBiggity]

nice work Mark!

[BMFR6]

Threw the shock in last night. This will be a fun bike to ride, but its going to be a workout!