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My 2000 yz 295 restoration build

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Thought i would start a thread with some photos of how my rebuild of my 00 yz250 is progressing.

I bought this bike about 6 months ago with a blown bottom end with intentions of fixing it a selling it, but 1 thing les to another and it ended up being a full rebuild for myself haha.

How i got it IMG_20161012_195706.jpg.6b166da39962fec0119d269b82270d9b.jpg

Pulled the top end apart a found some nasties due to the big end roller bearing letting go 

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Decided at this point to strip the frame down to nothing so i could repair a few broken brackets and get the frames ready to send off for powdercoatimg 

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Then started the engine teardown.... this is where i started hemeraging money.

Everything was knackered, required a newwaterpump drive, waterpump seal kit, all transmission, governor and waterpump bearings, both main shafts, various gears, full hotrods bottom end kit, new clutch kit, and various small components that were damaged or completely missing from a half ass rebuild previous to my ownership full teardown and thorough clean before reassembly of all the new components. 

Should also state i had to source a new set of crank cases due to the stator side crank bearing spinning in the case... and no longer being a interference fit :/20161202_140200.thumb.jpg.3340aeef91c77c5b24150dff19ad41c6.jpg

 

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Couldnt put the bike together with the old dented expansion chamber and muffler so purchased a fmf fatty and fmf powercore 2 muffler to bolt on 20170306_202225.jpg.11373d7674c99dfbbdc9e9c7fa873b71.jpg

I had to rig up the exhaust with the old cases so i could fabricate the broken and missing exhaust brackets so it would bolt up as it should. 20170318_185932.thumb.jpg.905bd578b02f0117da945555b27f7491.jpg

Couldnt have all this extra power and no extra stopping power, so a 270mm rotor and adaptor bracket was purchased. 20170322_232224.thumb.jpg.775a3c0a0d14843e27de2b0ff61d8724.jpg

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At some stage in its life it had the barrel removed and a steel sleeve fitted... the steel sleeve was never relieved enough to allow the powervalves to completely close so im sure it would of been lacking alot of low end power....

 

I weighed up alot of options, sourcing a new barrel a staying 250ccpurchase an athena 300 kit, purchase a 325 kit from the states... these interested me as they came with a new barrel...

In the end i decided to source a new 2nd hand barrel and send it off to two stroke performance for him to work his magic on a 295cc big bore kit 

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How the bike currently stands, awaiting recieving the frame back from sand blasters again so i can send it to powdercoaters and get some colour on it. 

SStill unsure what colour to go? Im thinking to stay with a blue similar to factory.... or maybe black, any ideas? 20170531_190845.thumb.jpg.e4e4ceb238dc7f69b9ea67189231bd7f.jpg

 

Also bottom end is just awaiting the return of the 295 kit and clutch to arrive ithe mail to be complete. 20170522_213527.jpg.08d0f8551cffc3df139e644e3b8d1552.jpg

 

Once frame is together i can concentrate on getting the rest of the components fitted up. The rebuild has taken some time due to doing bits a pieces when funds allow, but in the end i hope it will be eeverything i want and it will be how i pictured it. 

 

I will add more pics as the build progresses, but now its a waiting game for the critical components to arrive

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For people with early steel frame yz 250s. What options are out there to modernise the exterior of the bike? Aka plastic conversions, everything i have found is 02 onwards which is a pain in the ass 

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Nothing you can do for the 01 down. All 02 up plastics interchange. 

There is the moving of the lower brackets of subframe, and then a home made way of mounting the fuel cell to the frame for all 02 up stuff. 

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Just sos pads and a homemade soda blaster. Located in tassie 

 

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So dropped off a picked up my frame from the powdercoaters today. Decided to stick with a similar blue to factory. Extremely happy with it!! So the reassembly can now begin!!! 

 

Also got news from two stroke performance that the 295cc top end will begin next week so its finally taking shape!!!!

 

Il throw some pictures up tonight 

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20170608_211742.thumb.jpg.58a19cd0b035de79e76b95b01e52add0.jpg

Well here it is in all its glory :) finally starting to take shape. 

Will need to purchase a good bolt kit to piece all the new components together though, i seemed to forget about that haha. 

As much as it would of been nice to 2pac paint the frame and have the colour exactly the way i wanted it, i was worried about the chipping.... so powdercoat it was. They didnt have a huge selection of colours to choose from but im happy with this

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20170609_185228.thumb.jpg.7ae091255701cff179dc95f6cee04b00.jpg

Clutch kit and springs have arrived so its time to button up the bottom end... all thats left for bottom end is a boyesen highflow waterpump kit. 

 

Whats peoples opinions on preparing the clutch plates before fitting? I wont be installing them until the bikes pretty much ready to fire up 

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31 minutes ago, S.O.A.N.Z said:

soak the plates in oil first

Cheers mate, best to leave soaking overnight or longer?

 

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On 03/06/2017 at 10:08 AM, Wilksy said:

For people with early steel frame yz 250s. What options are out there to modernise the exterior of the bike? Aka plastic conversions, everything i have found is 02 onwards which is a pain in the ass 

Congrats on your project bike coming together.  What's your planned type of riding on it?

Here is a 2002 frame for AUD250 http://www.ebay.com.au/itm/2002-YAMAHA-YZ250-FRAME-/332167737165

With that and a subframe you could fit a 2002-15 or 2015-17 tank + plastics. Hopefully your 2000 swingarm would fit.

Or just get creative and make the 2002+ bodywork fit your frame.

Have you rebuilt your suspension yet?

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