1992 YZ250 lockdown-teardown- completed with start up video

sandman768
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sandman768 4/21/2020 2:46pm
4/21/2020 2:46pm
Bought a pivot works swingarm kit... pretty impressed it came with the side thrust bearings vs the plastic that come in some other kits. This kit even had the extra shim spacer that goes on the left side outer swingarm cup...not in the photo
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sandman768
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sandman768 4/21/2020 2:50pm
4/21/2020 2:50pm
Keep going on the swingarm... oem chain slider, UFO rear guide & slider and Oem chain adjuster nuts & bolts




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sandman768
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sandman768 4/22/2020 2:43pm
4/22/2020 2:43pm
Rear brake master cylinder and caliper rebuilds...





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The Shop

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gantry25
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gantry25 4/23/2020 7:57pm
4/23/2020 7:57pm
Really liking this build, brakes look fantastic! Keep the pictures coming!
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sandman768
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sandman768 4/24/2020 4:44am
4/24/2020 4:44am
gantry25 wrote:
Really liking this build, brakes look fantastic! Keep the pictures coming!
Thanks gantry25.... the vapor blasting really works good on the raw brake calipers...
sandman768
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sandman768 4/24/2020 10:56am
4/24/2020 10:56am
Big thank you to fellow Vital member Shue415 for saving this build ! My bottom end was basically junk from the previous owners hack job. Shue415 sold me a very nice bottom end for a very reasonable price. Thanks again....

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NiekL
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NiekL 4/24/2020 11:25pm
4/24/2020 11:25pm
sandman768 wrote:
Big thank you to fellow Vital member Shue415 for saving this build ! My bottom end was basically junk from the previous owners hack job. Shue415...
Big thank you to fellow Vital member Shue415 for saving this build ! My bottom end was basically junk from the previous owners hack job. Shue415 sold me a very nice bottom end for a very reasonable price. Thanks again....

That is a good thing about sharing your build and help each other out! With those old bikes finding new parts / or useable is not always easy.
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sandman768
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sandman768 4/25/2020 6:57am
4/25/2020 6:57am
NiekL wrote:
That is a good thing about sharing your build and help each other out! With those old bikes finding new parts / or useable is not...
That is a good thing about sharing your build and help each other out! With those old bikes finding new parts / or useable is not always easy.
Agreed.... best part about Vital are the builds and like minded people helping each other
2
SmokinJoe439 4/25/2020 9:16pm
4/25/2020 9:16pm
Do you remember these green with blue oem style graphics kits from 92.


sandman768
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sandman768 4/26/2020 6:05am
4/26/2020 6:05am
SmokinJoe439 wrote:
Do you remember these green with blue oem style graphics kits from 92. [img]https://p.vitalmx.com/photos/forums/2020/04/25/423080/s1200_Screenshot_20200425_205652_Chrome.jpg[/img]
Do you remember these green with blue oem style graphics kits from 92.


I have never seen that photo or the graphics! At the time, I was not into Yamahas, I was a Kawasaki guy, then Honda’s.
The Moto Log
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The Moto Log 4/26/2020 7:36am
4/26/2020 7:36am
looks awesome! I had a 125 from that area. I will always have a soft spot for those years. What did you use for installing the linkage and swingers bearings?
sandman768
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sandman768 4/26/2020 2:40pm
4/26/2020 2:40pm
The Moto Log wrote:
looks awesome! I had a 125 from that area. I will always have a soft spot for those years. What did you use for installing the...
looks awesome! I had a 125 from that area. I will always have a soft spot for those years. What did you use for installing the linkage and swingers bearings?
I use the heat/ freeze method with my bench top vice & sockets..some small, blocks of wood on the side that clamps on the part so no marks on the part. Sometimes can be a little tricky with something like the swingarm, as you have to balance everything when first starting the bearing, once it’s started correctly it’s nice & easy.
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smezmx
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smezmx 4/27/2020 10:14am
4/27/2020 10:14am
SmokinJoe439 wrote:
Do you remember these green with blue oem style graphics kits from 92. [img]https://p.vitalmx.com/photos/forums/2020/04/25/423080/s1200_Screenshot_20200425_205652_Chrome.jpg[/img]
Do you remember these green with blue oem style graphics kits from 92.


sandman768 wrote:
I have never seen that photo or the graphics! At the time, I was not into Yamahas, I was a Kawasaki guy, then Honda’s.
Green can work .......maybe? Smile



.



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sandman768
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sandman768 4/27/2020 12:54pm
4/27/2020 12:54pm
That looks nice....I”m totally embracing the magenta!
sandman768
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sandman768 4/27/2020 12:59pm
4/27/2020 12:59pm
Cases prepped...new crank bearings & seals... Test run on transmission installation..everything works as it should.



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shue415
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shue415 4/27/2020 3:32pm
4/27/2020 3:32pm
Wow,those cases cleaned up nice!
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sandman768
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sandman768 4/27/2020 3:49pm
4/27/2020 3:49pm Edited Date/Time 4/27/2020 3:50pm
shue415 wrote:
Wow,those cases cleaned up nice!
Planned on having cases vapor blasted.... after spending a few hrs cleaning them, they don’t need to be blasted. The trans bearings are all good. I just replaced mains & all seals. The silver finish is still good on most areas. When I get the bottom end done, I will refinish the cases to match the silver. The gasket surfaces are like new, if someone ever split the cases they knew what they were doing. No amount of work would have saved the original cases! Thanks man!
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Pit Row

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sandman768
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sandman768 4/30/2020 5:35pm
4/30/2020 5:35pm
I have 2 bottom ends now to compare & choose best parts for reassembling.
Basket on left is much better than original, these baskets are NLA, I lighty filed the tangs
Kicker spring on right is bent where it goes into the case locating hole & about to break...
SmokinJoe439 4/30/2020 6:51pm
4/30/2020 6:51pm
Mitaka uk has a billet clutch basket listed for the 89 - 92 yz250.
sandman768
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sandman768 5/1/2020 5:15am
5/1/2020 5:15am
SmokinJoe439 wrote:
Mitaka uk has a billet clutch basket listed for the 89 - 92 yz250.
Correct...wonder if we have any importers for Mitaka parts in USA?
sandman768
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sandman768 5/4/2020 12:32pm
5/4/2020 12:32pm
All new seals... I forgot to order a water pump seal!

had to remove a fork cap to get a broken air bleed screw out...


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sandman768
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sandman768 5/4/2020 12:34pm
5/4/2020 12:34pm
Sent cylinder out to Powersealusa in Pa. just received email from them, 4-5 weeks out... good to be busy....
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sandman768
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sandman768 5/5/2020 4:05pm
5/5/2020 4:05pm
Vapor blasted triples... new aluminum spanner nut/sleeve... a little over engineered triple clamp setup

Only have my lift open for a few days, going to try & get this thing rolling so it’s not sitting in boxes on my garage floor!
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sandman768
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sandman768 5/6/2020 12:58pm
5/6/2020 12:58pm
After some fine tuning with a die grinder and a heat gun... I have this rear fender/ side panel/ seat combo about good as it will get.


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Bent206
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Bent206 5/8/2020 5:58am
5/8/2020 5:58am
sandman768 wrote:
After some fine tuning with a die grinder and a heat gun... I have this rear fender/ side panel/ seat combo about good as it will...
After some fine tuning with a die grinder and a heat gun... I have this rear fender/ side panel/ seat combo about good as it will get.


The fit-up probably didn't look that good from Yamaha when it was new.
Considering what it looked like when you bought it, that looks great!
sandman768
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sandman768 5/8/2020 6:50am
5/8/2020 6:50am
Bent206 wrote:
The fit-up probably didn't look that good from Yamaha when it was new.
Considering what it looked like when you bought it, that looks great!
Thanks, you are most likely correct on fit... I know the rear subframe rails are correct, the seat, side panels & silencer all fit correctly. The p.o. Had the fender mount holes drilled out to fit the misaligned rear rails. Just a little massaging with the die grinder on the fender mount points gave me some adjustment. Now I can move on to fitting new seat foam & cover and prepping plastic for Evo-MX oem decal kit👍
gantry25
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gantry25 5/8/2020 8:54am
5/8/2020 8:54am
Bent206 wrote:
The fit-up probably didn't look that good from Yamaha when it was new.
Considering what it looked like when you bought it, that looks great!
sandman768 wrote:
Thanks, you are most likely correct on fit... I know the rear subframe rails are correct, the seat, side panels & silencer all fit correctly. The...
Thanks, you are most likely correct on fit... I know the rear subframe rails are correct, the seat, side panels & silencer all fit correctly. The p.o. Had the fender mount holes drilled out to fit the misaligned rear rails. Just a little massaging with the die grinder on the fender mount points gave me some adjustment. Now I can move on to fitting new seat foam & cover and prepping plastic for Evo-MX oem decal kit👍
Nice job on the plastic alignment!

Sounds like you're happy with the Pivot Works stuff, no need to go OEM on bearing assemblies? Guess I'll go that route as well just hadn't heard that much feedback on them.

I have one of these bikes that I will be working on after I complete the 1999 YZ I am currently building. Love these 92 YZ's, I will be embracing the magenta as well with my build!
sandman768
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sandman768 5/8/2020 1:28pm
5/8/2020 1:28pm
Water pump seal came last nite... pita getting the old one out! Blind side bearing puller worked good!

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