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offrdr1975 11-04-2012 05:08 PM

Rebuilding a 1989 Yamaha YZ250
The real title of this thread should be rebuilding my youth. I got my first 89 YZ250 when I was about 15 years old after moving up from a couple of older YZ125s. I had this bike for around 4 years. During that period My dad, brother and I were riding a lot and I have a lot of great memories from those years. About a year ago I was looking through Craigslist and came across the listing for this bike After looking at the bike I couldn't help myself and it followed me home. While being in pretty good shape for a 23 year old bike I have decided to do a restoration on the bike and return it to its former glory. This will be a slow process between work and life getting in the way, but I wanted to document it here. This bike is actually in better shape than my original was when I got it in 1991. Below are some pictures of the bike and its tear down.

And Hopefully it will end up looking something like this.

agspecialties 11-04-2012 06:11 PM

That bike looks really good for being that old of a bike. Should be a great and easy project for you. Looks like the bike is all there. Did it run? Keep us posted.

THB 11-04-2012 06:17 PM

Tugging at heartstrings. I have two boys and gave my son his first YZ250 at the age of 15 also. It's a 2003 and still putting many a mile and many a smile on both of our faces. I hope he feels the same way years down the road. Best of luck with the rebuild.

Gham 11-04-2012 06:20 PM

Looks waaaay better than my 87 CR250R (that needs a crank:cry$$$$$)

Best of luck,looks fairly easy like was said above^^

offrdr1975 11-04-2012 06:50 PM

Thanks guys. Overall it is in pretty good shape. It needs a thorough cleaning, painting, and overall refreshing. Motor runs good and had new crank seals installed shortly before I purchased it so I am not sure how much I will do to it. All the suspension needs rebuilt and the wheels need some work. Overall though it is a good base to start with. I already have all new plastic and graphics for it. I am looking into powder coating the frame if it is not too cost prohibitive. Should be a fun winter project.

third eye 11-04-2012 08:30 PM

Is that carb a mikuni VM? Just curious as my '93 WR250 had one

offrdr1975 11-04-2012 08:42 PM

It is actually a Mikuni TM, but I would have to research further to tell you what size of TM.

offrdr1975 11-06-2012 07:29 PM

Well after getting quotes for powder coating the frame I am getting it powder coated. Other than that just ordering parts while I am out of town this week.

Gham 11-07-2012 12:51 PM

I've never had one powder coated but some of those who have remarked about too much paint build-up in the neck(makes the bearings difficult to re-fit) just a tip in case you have never had one done before.You probably already knew this though

offrdr1975 11-07-2012 05:39 PM

Since my steering head bearings are bad I plan to leave the old bearing races in until after it is powder coated. Hopefully this will help prevent this issue.

third eye 11-07-2012 07:17 PM

good decision on the old races in the steering head. I seen someone do that before and it worked out well. Need to paint the frame on my WR but too busy riding it.

PTRadam 11-08-2012 11:03 AM

Reminds me of Damon Bradshaw!

Gham 11-08-2012 01:44 PM


Originally Posted by offrdr1975 (Post 19995256)
Since my steering head bearings are bad I plan to leave the old bearing races in until after it is powder coated. Hopefully this will help prevent this issue.

Smart move!

offrdr1975 11-09-2012 10:10 PM

Finally back in town. I dropped the frame off at the powder coaters tonight. I cant wait to see it finished. I also took the opportunity to clean up and inspect a few parts getting them ready for reinstall.

First cleaned up and repainted the top triple clamp. I also installed the lower bearing on the steering stem.

Next I checked out the front rim. Several spokes were loose and some were corroded solid so I took the wheel apart and cleaned and painted the hub to get it ready to be relaced.

I also cleaned up the swing arm and linkages trying to get them ready to go back on. So far all of the linkage bearings appear to be in good shape. No signs of pitting or rust and had lots of grease in them. Unfortunately tonight will probably be the last time I get a chance to work on it until after Thanksgiving though.

offrdr1975 11-27-2012 10:37 PM

Got the frame back from the powder coaters
Well after a week of vacation I was excited to get back to town so I could get my frame which was ready at the Powder Coaters. They did a great job with a lot of attention to detail. They protected all of the threads and mounting points. They also protected the VIN so that it can still be easily read. Overall I am very happy with the work and I thought the price was very reasonable. To media blast and powder coat the frame they only charged $175 which I was very happy with. I was not able to get a lot done tonight other than chasing the threads on the frame. Hopefully I will have some time this weekend to make some real progress on the bike.

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