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Old 06-17-2014, 10:30 AM   #1
Mirrory OP
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Oddometer: 5
Wicked 1991 WR250Z Rebuild & Supermoto convert

Hey everyone! I'm restoring a 1991 WR250Z and a 1998 KX250L and will be plating them and turning them into some sweet vintage supermotos. The 91 WR250Z is as old as me, and looked like it was never maintained. Pretty much every bearing (actually EVERY bearing, except the steering stem bearings which were new) and anything rubber was shot. Suspension linkage totally destroyed, some bearings were even completely missing!

Link to unordered album here

Carb had a ton of corrosion in it


The bike was in really bad condition, and had evidence it had been on fire for a brief moment. You can see the KX250L and my Street Triple stunt bike in the background:





Tearing the head off, I was greeted with this mess:





Found this engraved on the side. Turns out they're still in business over in Garland, TX (I'm in Plano, TX and the bike was found way out in Fort Worth)
I'm fairly certain the race team that used this bike in 1991 was the last person/group to maintain it.



The frame was EXTREMELY light! It surprised my friend. We thought it was stainless steel until we picked it up. Turns out it's chromolly, and VERY light (Feels like sub 15 lbs, even with the triple and all the crap on it). That black bit is some kind of burnt crap. The relay arm was 'welded' in by rust. Ended up having to saw it off before powdercoating:



Shot of my friend after we swapped the front end on his SV650 and restored it in other ways. The bike looks even better now that the blue paintjob is finished:



Picking up the frame from the powdercoater, he did a fantastic job (Taylor's powderworks). Candy red!






Considering the condition of everything else, the transmission was in good shape. I didn't get many pictures of this process. I split the cases and replaced every bearing and seal in the crankcase, and rebuilt and trued the crankshaft:



Carefully pressing the case halves back together:



One of the old bolts snapped, didn't even really torque it down, ack



Yay! There's still some material to grab onto to extract it. Lucky day!




New piston, conrod and rebuilt crank:




In case you forgot what it used to look like at this point:




Freshly honed cylinder, it was gray before:



Putting the cylinder head cover and powervalve back on:




All together now! I lost the stupid plastic transmission oil fill plug though:



Fork rebuild madness!



Shock rebuild madness!





That mud you see is the shock oil and fork oil from both forks combined. They pretty much leaked all their fluid.



Swingarm rebuild time!



Well, shit.



Shit...







Fuck it, I'll buy a new swingarm (picked one up for $42 in great condition).

New rads!



Engine all mounted up




Stay tuned... will have more updates to come soon. I've mounted the swingarm and am building the wiring harness for a keyless NFC ignition, poor mans lojack, battery, reg/rec, trailtech vapor, headlight and tail light. (Turn signals not required here in TX)

Update:

Got the shock charged with nitrogen, mounted it up along with the swingarm.


Mirrory screwed with this post 06-23-2014 at 10:36 AM
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Old 06-18-2014, 06:56 PM   #2
YZEtc
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Looking good. :)

I owned a new 1990 YZ-250A1 back in those days.
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Old 06-18-2014, 08:27 PM   #3
MikeGayner
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This is going to be a fun project to watch.
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Old 06-19-2014, 07:01 AM   #4
third eye
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I have a '93 WR250, bought it two years ago with low hours on it. I'm interested to see if you can get that stock carb to work. Mine sucked, had to replaced it with a Keihin PWK. That needed a YZ250 throttle cable and new throttle to work
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Old 06-19-2014, 07:02 AM   #5
third eye
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Oh, where did you get the new radiators?
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Old 06-19-2014, 09:43 AM   #6
Mirrory OP
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Quote:
Originally Posted by third eye View Post
I have a '93 WR250, bought it two years ago with low hours on it. I'm interested to see if you can get that stock carb to work. Mine sucked, had to replaced it with a Keihin PWK. That needed a YZ250 throttle cable and new throttle to work
Believe it or not, the thing ran pretty good before I tore it down, nice crisp throttle response. Not the greatest but it will be pretty awesome when its finished. It was a former race bike so I believe they had it tuned pretty spot on for the bike, but I will probably be picking up an aftermarket carb.
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Old 06-19-2014, 09:45 AM   #7
Mirrory OP
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Originally Posted by third eye View Post
Oh, where did you get the new radiators?
I got it off of eBay for $90 shipped:

http://www.ebay.com/itm/261361818300...%3AMEBIDX%3AIT

Its pretty good quality, doesn't leak or anything when I tested it when I got it. I'm going to be putting waterless coolant in this bike so I figured I'd pick up a nice radiator that wasn't bent to shit.
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Old 06-19-2014, 06:05 PM   #8
third eye
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my original mikuni VM carb has brass floats. Judging by the look of yours, its obviously not the same. I'm tempted to make my bike a dual sport since I'm not too crazy about the wimpy 43mm forks even after I modified them. The motor is a whol lot of fun though
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Old 06-25-2014, 06:45 AM   #9
third eye
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Question

no update??
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Old 07-04-2014, 10:03 PM   #10
Sub Zero
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looks real good so far! any updates?? this is my 1994. tagged and titled.

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1994 WR250-Z | 1995 KX500 | 1998 KLX300 | 2004 CRF450R (Motard) | 2009 KX450F | 2001 XR650R | 1992 WR200R | 1992 WR500-Z | 1986 GPZ900 | 2005 RMZ450
"Great! What am I supposed to use now?! Harsh language?"
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Old 07-09-2014, 06:48 AM   #11
third eye
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^^^^^
What brand tail lamp and fender extension is that?
I'm in the middle of wiring up my bike to get plated.
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Old 07-09-2014, 07:38 PM   #12
Sub Zero
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Quote:
Originally Posted by third eye View Post
^^^^^
What brand tail lamp and fender extension is that?
I'm in the middle of wiring up my bike to get plated.

polisport! only 20$ online!
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1994 WR250-Z | 1995 KX500 | 1998 KLX300 | 2004 CRF450R (Motard) | 2009 KX450F | 2001 XR650R | 1992 WR200R | 1992 WR500-Z | 1986 GPZ900 | 2005 RMZ450
"Great! What am I supposed to use now?! Harsh language?"
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Old 07-24-2014, 05:04 AM   #13
ohgood
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cool rebuild. looks like it's gonna be sharp.

thanks for more ammo in my war on ez-outs
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scrolling through the words to get to the pictures is cool, but i'm really just here for the tracks and waypoints... post some ok ?
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Old 07-24-2014, 06:42 AM   #14
third eye
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thread went dead for some reason
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Old 07-24-2014, 09:01 PM   #15
jimroid
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I'd like to have a WR250 motor [with the wide ratio trans and charging coil]. These are cool bikes.Keep it coming.
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