My Restoration Project (56k don't bother)

[mandark1967]

This is the story about my 1998 YZ 250 that was initially picked up for cheap, then picked up for free, picked up again REALLY cheap, and is now making me pay for it, in full.

The Reader's Digest condensed version is:

I bought it for $1800. I put it up for sale a year later for $1700. Friend offered to sell bike for me and

the bike was stolen. Friend paid me $1700 and (once I gave him the Cert of Origin) filed police

report. 16 months later the bike is recovered. His wife won't let him keep it. I paid him $135 for

impound fees and get it back.

Here's what it looked like

http://img18.imageshack.us/img18/2476/1998yz25002fj3.jpg

Well, here's your problem!

http://img19.imageshack.us/img19/4910/1998yz25003uh1.jpg

Oohh...crushed radiator to boot!

http://img21.imageshack.us/img21/1791/1998yz25005mr1.jpg

Time for a project! Let's start ordering parts!

http://img11.imageshack.us/img11/498/1998yz25011oe9.jpg

 

[mandark1967]

Let's get more parts!
Item Name
HOLDER,LEVER 1 4851-001*|*Yamaha 1998 YZ250K1 HANDLE SWITCH - LEVER
HOLDER,LEVER LWR 1 776-001*|*Yamaha 1998 YZ250K1 HANDLE SWITCH - LEVER
LEVER L 4852-001*|*Yamaha 1998 YZ250K1 HANDLE SWITCH - LEVER
BOLT 4853-001*|*Yamaha 1998 YZ250K1 HANDLE SWITCH - LEVER
NUT,U 4804-001*|*Yamaha 1998 YZ250K1 HANDLE SWITCH - LEVER
BOLT 364484-001*|*Yamaha 1998 YZ250K1 HANDLE SWITCH - LEVER
BOLT 4854-001*|*Yamaha 1998 YZ250K1 HANDLE SWITCH - LEVER
NUT,SPEC'L SHAPE 4855-001*|*Yamaha 1998 YZ250K1 HANDLE SWITCH - LEVER
CABLE,THROTTLE 1 285663-001*|*Yamaha 1998 YZ250K1 STEERING HANDLE - CABLE
CABLE,THROTTLE 1 285663-001*|*Yamaha 1998 YZ250K1 STEERING HANDLE - CABLE
AIR CLEANER CASE A 2896-001*|*Yamaha 1998 YZ250K1 INTAKE
SEAL 851-001*|*Yamaha 1998 YZ250K1 INTAKE
COLLAR 622-001*|*Yamaha 1998 YZ250K1 FENDER
BOLT,WITH WASHER 5749-001*|*Yamaha 1998 YZ250K1 FENDER
PLUG,SPEC'L SHAPE 656-001*|*Yamaha 1998 YZ250K1 FRAME
SCREW,FLAT 5030-001*|*Yamaha 1998 YZ250K1 REAR ARM
PATCH A 4887-001*|*Yamaha 1998 YZ250K1 REAR ARM
COVER 4903-001*|*Yamaha 1998 YZ250K1 REAR ARM
SCREW,FLAT 5030-001*|*Yamaha 1998 YZ250K1 REAR ARM
PATCH A 4887-001*|*Yamaha 1998 YZ250K1 REAR ARM
COVER 4903-001*|*Yamaha 1998 YZ250K1 REAR ARM
BOLT, W/WASHER 2939-001*|*Yamaha 1998 YZ250K1 STEERING
COLLAR 631-001*|*Yamaha 1998 YZ250K1 SIDE COVER
BOLT,FLANGE 4988-001*|*Yamaha 1998 YZ250K1 SIDE COVER
NUT, SPRING (4ES) 1034-001*|*Yamaha 1998 YZ250K1 SIDE COVER
BRAKE PAD KIT 668-001*|*Yamaha 1998 YZ250K1 FRONT BRAKE - CALIPER
BRAKE PAD KIT, 2 5994-001*|*Yamaha 1998 YZ250K1 REAR BRAKE - CALIPER
HOLDER,LEVER 1 4851-001*|*Yamaha 1998 YZ250K1 HANDLE SWITCH - LEVER
HOLDER,LEVER LWR 1 776-001*|*Yamaha 1998 YZ250K1 HANDLE SWITCH - LEVER
LEVER L 4852-001*|*Yamaha 1998 YZ250K1 HANDLE SWITCH - LEVER
BOLT 4853-001*|*Yamaha 1998 YZ250K1 HANDLE SWITCH - LEVER
NUT,U 4804-001*|*Yamaha 1998 YZ250K1 HANDLE SWITCH - LEVER
BOLT 364484-001*|*Yamaha 1998 YZ250K1 HANDLE SWITCH - LEVER
BOLT 4854-001*|*Yamaha 1998 YZ250K1 HANDLE SWITCH - LEVER
NUT,SPEC'L SHAPE 4855-001*|*Yamaha 1998 YZ250K1 HANDLE SWITCH - LEVER
GROMMET 531083-001*|*Yamaha 1998 YZ250K1 RADIATOR - HOSE
COLLAR 4885-001*|*Yamaha 1998 YZ250K1 RADIATOR - HOSE
BOLT,SMALL FLANGE 626-001*|*Yamaha 1998 YZ250K1 RADIATOR - HOSE
WASHER,PLATE 4730-001*|*Yamaha 1998 YZ250K1 RADIATOR - HOSE
BOLT,BUTTON 357511-001*|*Yamaha 1998 YZ250K1 FRAME
BOLT,WASHER BASED 4499-001*|*Yamaha 1998 YZ250K1 FRAME
BOLT,FLANGE (4MY) 5739-001*|*Yamaha 1998 YZ250K1 FRAME
BOLT, FLANGE 363959-001*|*Yamaha 1998 YZ250K1 FRAME
WASHER,PLATE 346868-001*|*Yamaha 1998 YZ250K1 FRAME
NUT, SELF LOCKING 4512-001*|*Yamaha 1998 YZ250K1 FRAME
BOLT, FLANGE 363988-001*|*Yamaha 1998 YZ250K1 FRAME
WASHER 4744-001*|*Yamaha 1998 YZ250K1 FRAME
NUT,SELF-LOCKING 648-001*|*Yamaha 1998 YZ250K1 FRAME
BOLT,WASHER BASED 649-001*|*Yamaha 1998 YZ250K1 FRAME
BOLT,FLANGE(4MY) 1077-001*|*Yamaha 1998 YZ250K1 FRAME
TENSIONER 646-001*|*Yamaha 1998 YZ250K1 FRAME
TENSIONER 640-001*|*Yamaha 1998 YZ250K1 FRAME
BEARING 641-001*|*Yamaha 1998 YZ250K1 FRAME
COLLAR 4506-001*|*Yamaha 1998 YZ250K1 FRAME
BOLT, SMALL FLANGE 643-001*|*Yamaha 1998 YZ250K1 FRAME
NUT,SPEC'L SHAPE 346074-001*|*Yamaha 1998 YZ250K1 FRAME
WASHER, PLATE 4509-001*|*Yamaha 1998 YZ250K1 FRAME
CLAMP, HOSE 600-001*|*Yamaha 1998 YZ250K1 FRAME
NUT,ADJUSTING 722-001*|*Yamaha 1998 YZ250K1 FRONT MASTER CYLINDER
COLLAR,LEVER 1 723-001*|*Yamaha 1998 YZ250K1 FRONT MASTER CYLINDER
CIRCLIP (6L5) 4802-001*|*Yamaha 1998 YZ250K1 FRONT MASTER CYLINDER
CIRCLIP 725-001*|*Yamaha 1998 YZ250K1 FRONT MASTER CYLINDER
WASHER 726-001*|*Yamaha 1998 YZ250K1 FRONT MASTER CYLINDER
LEVER 2 285664-001*|*Yamaha 1998 YZ250K1 FRONT MASTER CYLINDER
COVER,HANDLE LEVER 732-001*|*Yamaha 1998 YZ250K1 FRONT MASTER CYLINDER
SPACER, BEARING 737-001*|*Yamaha 1998 YZ250K1 FRONT WHEEL
SPACER 4937-001*|*Yamaha 1998 YZ250K1 REAR WHEEL

 

[mandark1967]

Even More parts!

Item Name Quantity
GUIDE, CABLE 708-001*|*Yamaha 1998 YZ250K1 FRONT - FORK 1
HOLDER, DAMPER 753-001*|*Yamaha 1998 YZ250K1 FUEL TANK 1
GROMMET 4822-001*|*Yamaha 1998 YZ250K1 FUEL TANK 1
BOLT,WASHER BASED 342687-001*|*Yamaha 1998 YZ250K1 FUEL TANK 1
BOLT,WITH WASHER 531080-001*|*Yamaha 1998 YZ250K1 FUEL TANK 1
COLLAR 349840-001*|*Yamaha 1998 YZ250K1 FUEL TANK 1
SCREW,BINDING 4824-001*|*Yamaha 1998 YZ250K1 FUEL TANK 1
BRACKET,SEAT 758-001*|*Yamaha 1998 YZ250K1 FUEL TANK 1
SCREW,FLAT 4825-001*|*Yamaha 1998 YZ250K1 FUEL TANK 1
FUEL **** ASSY 1 4827-001*|*Yamaha 1998 YZ250K1 FUEL TANK 1
HOSE 351999-001*|*Yamaha 1998 YZ250K1 FUEL TANK 1
CLIP,SCISSOR 4831-001*|*Yamaha 1998 YZ250K1 FUEL TANK 4
WASHER,PLATE 4832-001*|*Yamaha 1998 YZ250K1 FUEL TANK 2
SCREW,SPEC'L SHAPE 767-001*|*Yamaha 1998 YZ250K1 FUEL TANK 2
OIL SEAL,DD-TYPE 882-001*|*Yamaha 1998 YZ250K1 REAR ARM 2
BOLT,HEX. SOCKET HEA 888-001*|*Yamaha 1998 YZ250K1 REAR ARM 4
BOLT, WASHER (4KG) 5760-001*|*Yamaha 1998 YZ250K1 REAR ARM 2
NUT, FLANGE 363629-001*|*Yamaha 1998 YZ250K1 REAR ARM 2
BOLT,FLANGE(4MY) 795-001*|*Yamaha 1998 YZ250K1 REAR ARM 1

Bike Bandit is too expensive so I went to other places, like Rocky Mountain ATV, and I had Jeremy

at MX-Tech completely re-do the front and rear suspension ($1400+ for hsi work alone)

EVEN MORE PARTS! SOMEONE STOP ME! PLEASE!!!!!
(note there are some dupes from my copy & pasting)

All New Suspension Linkage and Swing arm bearings
Actually, ALL wheel and steering and suspension bearings, washers, and/or caps replaced with

NOS parts
All New Clutch featuring:
• OEM Yamaha basket
• Heavy-Duty steel EBC plates for maximum life
• New EBC Heavy-Duty Fiber Friction Plates
• New EBC Heavy-Duty Clutch Springs
• New OEM Screws & Washers
• New OEM Yamaha Clutch Push Rod Assembly
• New OEM Yamaha Boss Clutch Assembly
• New OEM Yamaha Clutch Arm Assembly
• New OEM Yamaha Clutch Cover Gaskets
• New OEM Yamaha Clutch Bearings
New OEM Yamaha Clutch Cable
New FMF 909 Grips
New Boyesen RAD Valve Carbon Fiber Reeds and body
Jeremy at MX-Tech Rebuilt, Re-valved, & and Re-Sprung the Forks using MSR Seals and MX-Tech

Springs
Jeremy at MX-Tech Rebuilt, Re-valved, & Re-Sprung and Re-Charged Rear Shock using MSR

Seals and MX-Tech Springs
N-Style-Themed Graphics Kit
N-Style Grabber Seat Cover
New Acerbis Fenders (OEM Replica Style/Color -- Front & Back)
New Acerbis Side Covers (OEM Replica Style/Color)
New Acerbis Radiator Shrouds (OEM Replica Style/Color)
New Acerbis Front Number Plate (OEM Replica Style/Color)
New Acerbis Lower Fork Protectors (OEM Style/Color)
New Primary Drive Brand Steel Sprocket (Front)
New Primary Drive Brand Alloy Racing Sprocket (Back)
New Primary Drive Brand 520 O-Ring Chain
New Dunlop D739 Intermediate Terrain Tire up front
New Michellin Starcross Tire out back
New Moose Racing Gear Shifter
New Moose Racing Kill Switch
Cycra Large Capacity 3.7 Gallon Gas Tank
Heavier Flywheel
Factory Connection Frame Protectors
Factory Connection Skid Plate
Nickel-plated FMF Pipe (Painted black), with newly-repacked Turbine Core silencer

 

[mandark1967]

How it looked a month ago (serious hangtime! 1yr of hanging on the wall)

http://img11.imageshack.us/img11/7341/hangtimeog4.jpg

I pulled it down to take a look at it and didn't like the color.

http://img12.imageshack.us/img12/581/framefy2.jpg

So, I repainted it again. And replaced every bearing and bushing with ne wPivot Works or Moose or OEM (depending on the part's location) Repainted the Swing Arm too. It looked like ass, previously.

http://img9.imageshack.us/img9/6893/framepaintedfs8.jpg

Now that the frame is in decent shape, let's look at the motor!
The head isn't "horrible".

http://img24.imageshack.us/img24/6355/img0015sw8.jpg

 

[mandark1967]

The piston looks a bit "used", and the cylinder isn't in all that good a shape.

http://img23.imageshack.us/img23/3425/img0017gd3.jpg

http://img17.imageshack.us/img17/5893/img0016ij0.jpg

Those scratches are easily felt, and there are several flat spots and areas where the nikasil is worn down.

I shipped the cylinder to Millennium Technologies to be bored and replated so I could install this

http://img11.imageshack.us/img11/5474/img0047yy9.jpg

 

[mandark1967]

Did I mention I got more parts?

[/URL][/IMG]

While I had the jug off, I measured the bottom end clearance and it would seem I am .2mm out of spec for connecting rod slop.

Guess what? MORE PARTS!

I ordered the complete crank assembly and main bearings from DGY (they rock) and they should ship out to me today. Since I don't have a press and a case splitter and a flywheel puller, I contacted the local "reputable" cycle shop and fletch said he'd split the case, replace the main bearings, install the
crank assembly, and button it back up for me for $200.

Did I mention the power valve looked like a hooker's bum after a huge bachelor's party?

http://img21.imageshack.us/img21/4716/img0073ow7.jpg

Time to clean

http://img11.imageshack.us/img11/3037/img0117hj9.jpg

http://img22.imageshack.us/img22/962/img0126ed2.jpg

 

[mandark1967]

So where am I at now in the project?

I'm waiting on the crank to arrive so I can take the bottom end to fletch's and get it installed.
I'm waiting on the cylinder to get bored/honed out and replated to stock specs

Once those two tasks are completed, I'll be putting it back together

Here's what it looks like now:
http://img8.imageshack.us/img8/2945/img0112yj5.jpg

 

[Chili]

I've removed all the photo's and left them as links, if you'd like to include them directly in the post please resize them to no more than 800 pixels wide as per the forum rules.

 

[RM_guy]

Man, That's quite a project but you're gonna have a brand spanking new bike when you are done...maybe you can get some bailout money to help out :)

 

[John.Jr]

Atlease you know what you got!!!!!!!!!!! Im motorcycle crazy but I met my match,good luck mandark

 

[Patman]

Oh have I ever been dow this same road! It's fun though and tou get exactly what you want in the end. I just have to ask though, the bike was stolen your friend paid you $1700, the bike was recovered, are you going to give your friend back some of his $$ since you have the bike back?

 

[dirt bike dave]

Nice work!

You must really love that bike to put so much into it.

I'm a little afraid to ask how much $ you spent on parts and services to get a like new '98 YZ.

 

[mandark1967]

Oh have I ever been dow this same road! It's fun though and tou get exactly what you want in the end. I just have to ask though, the bike was stolen your friend paid you $1700, the bike was recovered, are you going to give your friend back some of his $$ since you have the bike back?

I'm debating whether or not to give him back some of the money.

 

[mandark1967]

Nice work!

You must really love that bike to put so much into it.

I'm a little afraid to ask how much $ you spent on parts and services to get a like new '98 YZ.

I haven't totalled it up yet, I'm afraid to, lol

 

[RM85rider123]

I haven't totalled it up yet, I'm afraid to, lol

I'm guessing $1000-$1500? It's probably more. :yikes:

 

[Patman]

Do bother totalling it up it will just make you second guess everything. You'll have a bike you love and you have put together the right way and that is worth a lot. I keep kicking around the idea of seeling mine but I keep on keeping it :)

At least with thinking about giving him something your on the right road to being a good friend. :cool:

 

[mandark1967]

Little more work done last night and today.

I washed out my cylinder last night and put the Power Valve gearing back into the clutch side of the case and installed the clutch case. It looks pretty darned sweet so far.





Today, I went to my friend's house where I keep the bike and completed the suspension installation. I'd only had my suspension bolts hand tightened because I had no torque wrench. (I replaced it today and torqued everything down nice and neat.

Then I started on the brakes (calipers, lines, etc) and discovered they are pretty damn hosed up. I'll need to do some serious work to get them straightened out.

 

[mandark1967]

After that, I remembered that I had to add the splash guard to the front of the air box so I drilled out the rivets on the old air box and moved the splash guard over and riveted it to the new airbox


Then I started throwing plastics and cables at the bike and this is what stuck





It's actually starting to look like a motorcycle again!

 

[mandark1967]

I shot the waterpump cover and clutch case with Duplicolor wheel paint. Man that silver really "pops"!

 

[NJGregsCR]

Looks great so far, make sure to keep the thread going, I can't wait to see it done

 

[DelSoto]

love it dude...doin the same to my 98 yz250
keep up the good work! It is nice to see these older bikes getting attention!

 

[kx125412]

Im with patman here. You will get the bike you want but im guessing the total price is going to be around 2000-2500. In Canada thats about what that bikes worth now, and with everything new it would be perfect. But in the states you guys give bikes away you probably couldve picked up an 03 or 04 bike for that price. Is that bike really worth it?

 

[_JOE_]

Some of us do it for the satisfaction of doing it. We enjoy it. You can't be worried about losing money when it comes to dirt bikes. They're terrible investments.

Great job by the way! Lookin good. :cool:

 

[aaronnaland]

Totally worth it. couldn't imagine handling my bike over to the local dealer to work on. hahaha five seasons in eveleth scares me. Hard work comes a long way to satisfaction when you do it yourself. and ride it yourself.

 

[mandark1967]

Im with patman here. You will get the bike you want but im guessing the total price is going to be around 2000-2500. In Canada thats about what that bikes worth now, and with everything new it would be perfect. But in the states you guys give bikes away you probably couldve picked up an 03 or 04 bike for that price. Is that bike really worth it?

Since I am nearing completion of the project, I'll be happy to say that you could almost double your high estimate of the total price.

If it is a seal, stud, dowel, bearing, bushing, or O-Ring, it was replaced. If It was rubber or plastic, it was replaced. If it was even close to being out of spec, it was replaced. If it had 70% life left, but was just a bitch of a part to get to, like tranny bearings/seals, it got replaced on principle because I don't wanna have to tear this bike apart again for another 11 years.

The only parts that weren't replaced spec'ed well within tolerances and was/are easy to access.

That's why I spent $4600.00

I could have picked up a 04-05 husky 450 for less than I have spent on this, but that isn't what this whole process is about. As has been stated by others, it's about the experience and taking something that was totally thrashed and given up on by others, and being able to restore it to pristine condition.

My only regret is that this project was not done on a 1982 Suzuki RM250. I'd be very hard pressed not to do a straight trade for an `82 RM250 in any kind of decent shape.