96' yz250 to 04+ conversion complete

[chums179]

So this is my first post after lurking for, well, a long time.

I wanted to share my latest project.

I started with a rough 96'yz250 complete with Monster graphics.

Relocated the lower subframe mounts up about an inch or so, and added a small washer on either side of the upper mount to take up a little gap.

Bought a 98' swingarm to be able to use the updated chain guide bought misc 02+ parts including subframe airbox and plastics

I made up a tank mount to mount the 02+ tank and also made a lower shroud mount that bolts to the frame through the rad bolt and not the flimsy tab on the rad.I added an updated rear master along with front CR style line oversized nar mounts and many other little things.

Final product

[robbyboi86]

Very nice result

[YZDOC]

A whole lot a work. Came out very nice. Rewarding I hope.

Great job. ?

[chums179]

Yup, it was fun and I got to study up a lot on Yamaha's

I fix up a bike in my own style every winter and then sell it for another one to get creative with. I did a kx500 Aluminum Frame last year and went over the top!

[chums179]

[123caseyw]

Ooh I want af 500

Both bikes look killer

[UncleLuke]

Looks great!

 

Did the top subframe-to-frame bolt line up or need to be modded?

[chums179]

The top lined up perfectly, I added a small washer on each side of the frame bolt hole just to tighten the connection up but you really wouldn't have to

[johnk408]

Best first post ever? Usually it is, "What oil do i use" or "What graphics look best." Great work.

[chums179]

O forgot to mention from what I've read the 95-96 pipe is the only pipe that works on the 96 bike (may be more info that I don't know about) and then the 06' muffler just bolt right up to all the holes and the 96 pipe as it should.

Edited January 14, 2016 by chums179

[chums179]

Mount tab to attach lower shroud to bike

[chums179]

Revised tank mounts reach forward and down slightly more than stock reusing stock rubber mounts

[StillSmoking]

That's the best looking 96 YZ I've seen since the 90"s! It looks good without looking like it's trying too hard.

[UncleLuke]

The top lined up perfectly, I added a small washer on each side of the frame bolt hole just to tighten the connection up but you really wouldn't have to

 

Sweet, I think they moved the top mount back in 96 as the 93-95 models the top mount was higher and farther forward toward the tank

[chums179]

I like to keep things as stock as possible without additional custom parts. Keeping stock parts is often more work researching and head scratching than just making something up to get you to the next step but I like it when people walk by bikes I've done and assume they are factory until they really start to look, then its cool to see faces light up once they realize what's going on lol

[mjs113]

I know this is a old thread , but I have a Frankenstein 96 that I have done the tank conversion on , after seeing this thinking about doing subframe , airbox , seat etc.

I have a question about the swingarm swap you did on this . what lower shock linkage did you use? 96? 98?