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YZ250 project bike - need some information

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Almost three years ago, I started a YZ250 project. I basically started with a clean frame and had to purchase every single part for the bike. The point is to built the bike for enduro, but not to spend too much money right away. I barely noticed paying for the parts as every month I bought some part and it wasn't too expensive.

I did a lot of research and wanted to make my bike to be like 2015 model, but I failed in some segments. However, that isn't the point now. I have two questions, one regarding the exhaust and the other about rotor and stator.

 

Lets start with exhaust. I bought a used one from eBay. From what I know, it fits 1999-2017 YZ250. That is what I thought, but my chamber doesn't fit. I don't know why, but it touches either frame or radiator (replacement ones from eBay, but I don't think they are the problem). So my question is are all chambers the same (1999-2017) or I should buy a newer one? If they are the same, I would assume that my chamber is bent and therefore touches the frame? The radiators shouldn't be a problem?

The second question is about stator and rotor. From what I learned, 2003+ should be the same? I have 2006 stator, can I use a rotor from 2003? What are the differences between different stators and rotors on 2002-20017 YZ250?

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I would assume pipe is bent if it's that far off. 99-17 should fit based on what I've seen.

Good lookin' bike!

Edited by silent_matt

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Your missing a bracket where it attaches to the frame. Its 2 8mm or 6mm bolts I believe, a metal hanger with a rubber damper. 

https://www.manualslib.com/manual/196056/Yamaha-Yz250.html?page=15#manual  check out this page, you can see the two brackets. The one that you pointed it is as I described. Once you review the photo it will make sense. 

As far as the pipe touching the frame, you made need to tweak the pipe a bit. Worst case, just take a ball peen and tap that area in towards the pipe. BRAAPPPPPPPPP!!!!

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Pipe is bent, should fit flush on spigot of jug. You are missing a small bracket on back of chamber as mentioned. Do you have the front lower one also? 

2002 rotor/flywheel will not work on 2003-2017 crank. Did you manage to get a 03 up crank, or is the nut shaft 10mm not 12mm. 

Stator I believe to be same. 

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I do have both lower and upper exhaust brackets, they are just missing on the images since I can't mount the chamber. I also have 2002 rotor, but can't mount it on the 2003 crank. So I'm currently trying to find one for my bike, but wanted to make sure they are the same from 2003.

I will try to fix the pipe tonight or tomorrow. Will let you know. Thanks for the help! :)

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Use a piece of 2x2 or whatever fits in the exhaust flange hole. Just put it on something soft, one hand on the lever (piece of wood) and the other on the silencer side of the pipe and give it some elbow grease. Pipes are tough, so don't think you will damage it. Just massage it into shape. 

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While trying to find a rotor, learned a few more things. I thought that wiring harness is the same from 2002 up to 2017 (with the addition of connector for neutral switch assy), but it looks like there are some small differences.

I have CDI and ignition coil from 2002, but wiring from 2005 model. Do I need new wiring or I can modify the existing? Check the images? And are there any differences between CDIs?

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Edited by Quake

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