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YAMAHA RZR 250 YPVS, Resuscitation

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Suntan Sid
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PostPosted: 10:14 - 28 Jun 2010    Post subject: YAMAHA RZR 250 YPVS, Resuscitation Reply with quote
Well, I got it home on Friday night; yep it’s a bit ropey but essentially all there.

Apart from showing its age, (26 years), it’s pretty much what I expected. It’s been down the road at some time, very light cosmetic damage, (RH side).
A limited amount of dismantling, at the weekend, revealed the following:-

Bad points,
No battery.
May need a new wiring loom.
Forks are “forked” so to speak. A bit of pitting high up.

Plus points:-
It’s a runner.
Pretty much all original
17” wheels
Twin discs up front, rear disc.

Thar’ she blows!

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/RZR%20250/P1010183.jpg

Looks Ok in the sun

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/RZR%20250/P1010184.jpg

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/RZR%20250/P1010186.jpg

The bike is a “29L”, if anyone has any info they can pass on about this particular model I’d appreciate it. I would particularly like to know what parts, if any, are interchangeable with other models. Having seen before and after pictures of ”Marjays” bike I would guess that a lot of the running gear is the same.

My initial thoughts were to, simply tidy it up and get it on the road asap. Having mulled things over, I’m thinking of a more thorough rebuild.

I haven’t got the time to go at this hammer and tongs so don’t expect daily updates.

Is this pipe from the fuel tank really supposed to be there?

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/RZR%20250/P1010189.jpg

First job was unseizing the front brake callipers, which I achieved, however not having a manual, and after extensive “Googling” I can’t identify these callipers.

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/RZR%20250/P1010196.jpg

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/RZR%20250/P1010195.jpg


I would like to overhaul them but what part numbers do I need for new seals etc.?
Secondly do I need to split these callipers to get the pistons out?

Wish me Luck
Sid
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ms51ves3
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PostPosted: 10:50 - 28 Jun 2010    Post subject: Reply with quote
The pipe on the tank is supposed to be there.

If the seals in the calipers aren't leaking, I wouldn't replace them, just give the grooves in the caliper a good clean like I did on mine.
I've done 2,400 miles on my rebuilt calipers without any issues.

You don't need to split the caliper to get the pistons out, what you need is a couple of pieces of wood and an allen key.

https://i15.photobucket.com/albums/a376/ms51ves3/Pistonremoval.jpg

So push the pistons back into the caliper then pump one out like demonstrated above. This is how I did my rear caliper which looks the same or very similar to yours.

As you have disconnected the caliper, you will need a compressor to get the pistons out. Depending on how seized they are, you may get away with using a 12v compressor like I did.
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Welshd1k
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PostPosted: 10:50 - 28 Jun 2010    Post subject: Reply with quote
got a set of FZR wheels on it yes? because they certainly aint ypvs wheels.

i'd look at upgrading the calipers and a steerign damper Very Happy
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Suntan Sid
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PostPosted: 11:03 - 28 Jun 2010    Post subject: Reply with quote
ms51ves3 wrote:
The pipe on the tank is supposed to be there.

If the seals in the calipers aren't leaking, I wouldn't replace them, just give the grooves in the caliper a good clean like I did on mine.
I've done 2,400 miles on my rebuilt calipers without any issues.

You don't need to split the caliper to get the pistons out, what you need is a couple of pieces of wood and an allen key.

https://i15.photobucket.com/albums/a376/ms51ves3/Pistonremoval.jpg

So push the pistons back into the caliper then pump one out like demonstrated above. This is how I did my rear caliper which looks the same or very similar to yours.

As you have disconnected the caliper, you will need a compressor to get the pistons out. Depending on how seized they are, you may get away with using a 12v compressor like I did.


That's roughly how I got the pistons moving, I was wondering will one piston have enough room to be removed without splitting the calliper?

Do you know what these callipers are, I've looked at loads of parts fiches over the weekend but couldn't find them?
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MarJay
But it's British!



Joined: 15 Sep 2003
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PostPosted: 11:05 - 28 Jun 2010    Post subject: Reply with quote
Looks like the important bits are there, in which case I'd be pleased. As I said in the other thread the tank is a key part that is almost impossible to locate second hand. If its rust free then try to keep it that way.


I'd be well pleased with that! Smile Thumbs Up
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Suntan Sid
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PostPosted: 11:06 - 28 Jun 2010    Post subject: Reply with quote
Welshd1k wrote:
got a set of FZR wheels on it yes? because they certainly aint ypvs wheels.

i'd look at upgrading the calipers and a steerign damper Very Happy


I wouldn't know a set of FZR wheels If I tripped over them, I'd assumed they weren't standard.

Will any better forks slot in?
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ms51ves3
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PostPosted: 12:47 - 28 Jun 2010    Post subject: Reply with quote
Suntan Sid wrote:
That's roughly how I got the pistons moving, I was wondering will one piston have enough room to be removed without splitting the calliper?

Do you know what these callipers are, I've looked at loads of parts fiches over the weekend but couldn't find them?


If you push a piston all the way into the caliper body you should be able to get the opposing piston out.

Not sure what calipers they are. Could you not measure the piston and find out from that?
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Suntan Sid
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PostPosted: 13:20 - 28 Jun 2010    Post subject: Reply with quote
Yep, i'll be dusting off the Verniers tomorrow!
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MarJay
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PostPosted: 13:48 - 28 Jun 2010    Post subject: Reply with quote
Suntan Sid wrote:
Welshd1k wrote:
got a set of FZR wheels on it yes? because they certainly aint ypvs wheels.

i'd look at upgrading the calipers and a steerign damper Very Happy


I wouldn't know a set of FZR wheels If I tripped over them, I'd assumed they weren't standard.

Will any better forks slot in?


Not easily. You'd be better off getting cartridge emulators for those forks if you want to upgrade, but I found the forks on mine to be perfectly fine for a bit of scratching.
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Remember kids, bikes aren't like lego. You can't easily take a part from one bike and then fit it to another.
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Billing
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PostPosted: 00:08 - 29 Jun 2010    Post subject: Reply with quote
Welshd1k wrote:
got a set of FZR wheels on it yes? because they certainly aint ypvs wheels.


from a quick google it appears they are the standard wheels for this bike Thumbs Up
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Suntan Sid
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PostPosted: 10:30 - 29 Jun 2010    Post subject: Reply with quote
They're preload ajusters,!
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MarJay
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PostPosted: 10:45 - 29 Jun 2010    Post subject: Reply with quote
So its an RD350 YPVS with a 250 top end and TZR250 running gear...

If I had it I'd stick a 350 top end on it and go and hunt sportsbikes...
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Suntan Sid
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PostPosted: 12:50 - 29 Jun 2010    Post subject: Reply with quote
Whilst googling away I’m pretty certain that I read somewhere that swapping the top end for a 350 is not as easy as it sounds, in that you need to change a lot of other parts as well. Can’t remember the list of the top of my head but I’m pretty certain that CDi’s, oil pumps, servo motors and other stuff was mentioned to do a proper swap, any thoughts?

Having had a good look around on Fleabay, am I correct in thinking that most of the running gear/body work is interchangeable with a 31K?
Question
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ms51ves3
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PostPosted: 13:33 - 29 Jun 2010    Post subject: Reply with quote
Forks aren't the same as 2MA/1KT as they have the mounting points for two calipers. Could possibly have the same stanchions though.
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Kickstart
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PostPosted: 13:47 - 29 Jun 2010    Post subject: Reply with quote
Hi

Would suspect RD forks are rather longer than TZR forks. Might be the same basic design though.

All the best

Keith
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MarJay
But it's British!



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PostPosted: 15:30 - 29 Jun 2010    Post subject: Reply with quote
BLUEX5 wrote:
MarJay wrote:
So its an RD350 YPVS with a 250 top end and TZR250 running gear...

If I had it I'd stick a 350 top end on it and go and hunt sportsbikes...


Pretty much - although the chassis improvement budget fell short of 4 pot calipers for the front. The 250 variant will be quite lively but given the vast amount of 350 bits available I'd be dropping a top end on it. Might need the carbs too if the powerjet is different as they are a right bitch to change.


Mr Stanley Stephens told me to put a ball bearing in my powerjets to block 'em, and replace the mains with the jets from the first powervalve, the LC2. He said the reason Yamaha changed them was because they weren't meeting their warranty period before needing a rebuild... Apparently making this change makes the bike very very fast indeed.
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British beauty: Triumph Street Triple R; Loony stroker: KR1S; Track fun: GSXR750 L1; Commuter Missile: GSX-S1000F
Remember kids, bikes aren't like lego. You can't easily take a part from one bike and then fit it to another.
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Suntan Sid
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PostPosted: 21:06 - 14 Jul 2010    Post subject: Reply with quote
Well things are progressing, slowly.

I've identified the Model it's a 1988 "29L" like this one:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/RZR%20250/1988RZ250R.jpg

same wheels, brakes, exhausts, footrest hangers!

The brakes look exactly the same as the ones on this model, can anyone confirm this?:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/RZR%20250/548.jpg

The Good news:-
Power valves are not seized.
Bike was not wired for total loss, just required a battery.
Wheels are originals, sprayed red.

I've been stripping parts off the bike, cleaning them and noting what needs to be replaced.

All the rear mudguard has been off, cleaned and replaced.

There is a thick layer of Two stroke and dust covering virtually everything:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/RZR%20250/DUST2.jpg

Unfortunately no air filter present:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/RZR%20250/DUST3.jpg

2T Oil tank, errr oily!

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/RZR%20250/OILY2.jpg

Got the air box out of the frame, had to call a gynaecologist in though:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/RZR%20250/AIRBOXOUT.jpg

Carbs off, surprisingly all the rubbers are like new, amazing considering the climate out here, can anyone identify these carbs? I cant find any numbers on them.

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/RZR%20250/CARBS1.jpg

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/RZR%20250/CARBS2.jpg


Here's the exhausts as they came of the bike:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/RZR%20250/EXHAUST1.jpg

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/RZR%20250/EXHAUST2.jpg

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/RZR%20250/EXHAUST3.jpg

There are a couple of minor dents, not a lot I can do about them!
Can I buy aftermarket cans for these pipes?

After degreasing:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/RZR%20250/EXHAUST4.jpg

during painting with high temp paint:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/RZR%20250/EXHAUST5.jpg

Also removed from the bike are the chain which is in remarkably good nick, clocks and headlight.
In the post are:-

Ignition barrel.
Fuel pipes.
Twostroke oil feed pipes.
S/S exhaust studs.
Allen screw kit.
Exhaust gaskets.

I need to order:-
Brake piston seal kits (x6)
Indicator relay.
Headlight rim.
Indicators.
Air filter

Already purchased
Battery

Weird stuff:-
having done a fair bit of Googling, I have found out the following:-
According to the frame number it is a "29L" of 1988 vintage, according to the Log Book it's a 1986. No big deal Cypriot bureacracy is a total shambles, run by civil servants with Hitler complexes, therefore if it says 1986 on the Log book it must be 1986, there can be no mistake!
There is no engine number, well that's not strictly true, there is the model prefix "29L" but no further digits. No the numbers haven't been ground off, all the gnurling is still there.
Any ideas, anyone? What happens if you get a new engine under warranty, does it come with a number?
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Kickstart
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Joined: 04 Feb 2002
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PostPosted: 21:59 - 14 Jul 2010    Post subject: Reply with quote
Suntan Sid wrote:

There are a couple of minor dents, not a lot I can do about them!
Can I buy aftermarket cans for these pipes?


Not sure, but might be worth measuring them up and asking DEP. They look fairly similar to lower RD500 silencers which they do

Suntan Sid wrote:
There is no engine number, well that's not strictly true, there is the model prefix "29L" but no further digits. No the numbers haven't been ground off, all the gnurling is still there.
Any ideas, anyone? What happens if you get a new engine under warranty, does it come with a number?


Likely a Japanese market bike then. Quite common for Japanese market Yamahas not to have an engine number (my YSR doesn't have one either).

All the best

Keith
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ms51ves3
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PostPosted: 22:19 - 14 Jul 2010    Post subject: Reply with quote
Kickstart wrote:
Suntan Sid wrote:
There is no engine number, well that's not strictly true, there is the model prefix "29L" but no further digits. No the numbers haven't been ground off, all the gnurling is still there.
Any ideas, anyone? What happens if you get a new engine under warranty, does it come with a number?


Likely a Japanese market bike then. Quite common for Japanese market Yamahas not to have an engine number (my YSR doesn't have one either).

All the best

Keith


I know 3MAs don't have engine numbers either, possibly the same for the other Japanese market TZRs.
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serlant
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PostPosted: 23:53 - 14 Jul 2010    Post subject: Reply with quote
Suntan Sid wrote:
Well things are progressing, slowly.

I've identified the Model it's a 1988 "29L" like this one:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/RZR%20250/1988RZ250R.jpg

same wheels, brakes, exhausts, footrest hangers!

The brakes look exactly the same as the ones on this model, can anyone confirm this?:-

https://i645.photobucket.com/albums/uu172/Troodos-Pool-Guy/RZR%20250/548.jpg


calipers /discs on that 350 look like the same ones as the xj600 which i believe are different to yours as they have the pad pins on the top with a removable cover to slide the pads out of, would need a close up of that 350 to be sure.
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Suntan Sid
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Joined: 07 May 2009
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PostPosted: 06:45 - 15 Jul 2010    Post subject: Reply with quote
Quote:
Likely a Japanese market bike then. Quite common for Japanese market Yamahas not to have an engine number (my YSR doesn't have one either).


Quote:
I know 3MAs don't have engine numbers either, possibly the same for the other Japanese market TZRs.


Ok cheers for that, cleared up that little mystery. Thumbs Up

nevillemartin11 wrote:
I like the second one. It is look like very epic and also sweet. I thought that You have needed to surf your bike as well. So It would also look like as you have specified the photos here.


Well I've "googled" extensively and the only images, of my bike, I can find, are very low res, and, quite frankly, useless!

The brake issue: I've measured the pistons, they're 38mm diameter, does this size ring any bells?

Thanks for the feed back, I'll keep you informed of any progress, (likely to be slow). Cool
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