2000 Yamaha YZ250 frame with a 169FML motor project!

mebigdave · 01-30-2008, 06:04 PM

Iv'e just bought a 2000 Yamaha YZ250 rolling frame(just missing the YZ250 engine) and have also bought a brand new 200cc Shineray 169FML motor. My plan is to power the YZ with the China motor!

The new motor comes complete with CDI, carb, regulator, air box and ignition but no exhaust. I will have to look around for a cheap pipe and a FMF tail!

The rolling frame is only missing the motor and the exhaust!

I'm guessing that I will need to make some mods to the gear leaver as well as the rear brake leaver. Not to mention that the engine mounts will need to be done. I am a little worried that the motor may be a bit tall for the frame and tank?

I know I'm going to turn a lot of heads on trails... hehehe

Any thoughts or some handy input would go a long way!

liverchip · 01-30-2008, 06:11 PM

As I believe the throttle assembly on the Yammy is a push/pull design, you might have to come up with a new throttle tube as well.

liverchip · 01-30-2008, 06:15 PM

Sprocket/chain size will me an issue as well as I believe the motor comes with a 428 and the Yammy might have a 520.....Might need to get a 520 countershaft sprocket for the motor. Bruce should have them.

mebigdave · 01-30-2008, 06:18 PM

"Throttle assembly on the Yammy is a push/pull design"

Hmm.. didn't think about that!

mebigdave · 01-30-2008, 06:21 PM

I checked out the chain conversion from 428 to 520 and using the "gearing_calc.xls" speadsheet, I guess I will go with a 13T front and a 46T - 50T(STD) rear.

liverchip · 01-30-2008, 06:24 PM

Sounds like a very do-able project! Keep us posted.

mebigdave · 01-30-2008, 06:43 PM

Will do! I will be collecting the bike tomorrow night and the motor should arrive early next week. :wink:

TeamCheap · 01-30-2008, 07:55 PM

looks like a good / fun project.

The only real problem I can see is the exhaust but I'm sure you'll get that worked out, there are enough exhaust systems out there that one should fit it easy enough.

Once you get the spockets aligned perfectly and the engine mounts set it should all be down hill.

mebigdave · 01-30-2008, 08:35 PM

The more I look at the photos of the bike, the more worried I get about getting the head in under the tank! I guess I'll only know once I pickup the bike and can see under the tank.

Does anyone know if there is any way to mod a plactic tank?

warrior91 · 01-30-2008, 08:40 PM

Shim it up.

mebigdave · 01-30-2008, 08:43 PM

I'm thinking that there is not going to be enough space for the head to sit between the two lower halves of the tank?

katoranger · 02-01-2008, 03:17 PM

I will probably be tight, but I think you can get it in there.

Allen

mebigdave · 02-25-2008, 04:17 PM

Just a little update!

Over the last few weeks, I've stripped down the YZ250 and replaced the Swing arm bearings and seals, the Linkage bearing and seals, the lower shock bearing and seals and replaced the fork oil seals and dust seals. I've also spray painted most of the frame. The wheel bearings front and rear were in good condition so I did not have to replace then. I have packet every bolt and bearing with waterproof grease. I had a small number of spokes to tighten and a whole lot of greasing to do.

On the swing arm, the motor had a mount that the swing arm bolt went through. Because I'm using a 169FML motor I needed to make a bush to fit in place of the motor and this also stops the swing arm from bending inward. I've added a grease nipple to the bush so that I can pump grease onto the swing arm bolt.

Pictures to follow!

I've finished putting it all back together and it's looking the part again. I don't have the motor in yet but this will happen over the next two weeks. It's a bit tricky as the motor almost fits in the frame but is just a bit too tall to get the tappet cover in. I am going to have to cut the frame but will still use the frame around the motor to maintain the frames strength. I'm not going to use the same china bike design with having the motor as part of the frame. I don't think the mounts will be strong enough for the frame design.

Pictures to follow!

I'm now down to the last little bit to do like making a battery box frame to mount inside the old YZ250 air box and I am going to put the solenoid in there to for the electric start. I am also going to have to cut the tank away at the low part to allow for the top end of the motor to fit correctly. I guess I am going to have to learn real quick to plastic weld!

Funny thing is that the Intake manifold for the 163FML and the 169FML are different in the sense that the 163FML has the carburettor right behind the top end and the 169FML, the carburettor goes off at an angle!

There is not going to be enough space for the kick start(thank god) so it will be electric start or push start.

I've ordered the following parts to finish off the bike build:

2x Pairs of black grips. (One pair for my son's bike)
1x Throttle cable
1x Clutch lever - Complete with perch
1x Clutch cable
1x Kill switch with the push to start like on the XY200GYE + twist throttle
1x 13 tooth 520 front sprocket (JTF 328)
1x 520 chain 120 links with master link
1x Intake manifold for the XY200GYE
1x Exhaust header pipe for the XY200GYE

I will still need to find a muffler at a good price to fit the "XYZ200"

I'll upload pictures tonight!

fatboy250 · 02-25-2008, 04:31 PM

Dude sounds awesome! Can't wait to see how it turns out.

TeamCheap · 02-25-2008, 06:10 PM

I was thinking about this project the other day, cant wait to see the pics.

01-30-2008, 06:04 PM	#1
mebigdave Join Date: Dec 2007 Location: New Zealand Posts: 196	2000 Yamaha YZ250 frame with a 169FML motor project! Iv'e just bought a 2000 Yamaha YZ250 rolling frame(just missing the YZ250 engine) and have also bought a brand new 200cc Shineray 169FML motor. My plan is to power the YZ with the China motor! The new motor comes complete with CDI, carb, regulator, air box and ignition but no exhaust. I will have to look around for a cheap pipe and a FMF tail! The rolling frame is only missing the motor and the exhaust! I'm guessing that I will need to make some mods to the gear leaver as well as the rear brake leaver. Not to mention that the engine mounts will need to be done. I am a little worried that the motor may be a bit tall for the frame and tank? I know I'm going to turn a lot of heads on trails... hehehe Any thoughts or some handy input would go a long way!
	0

01-30-2008, 06:11 PM	#2
liverchip Join Date: Nov 2006 Location: Mystery Spot Posts: 1,223	As I believe the throttle assembly on the Yammy is a push/pull design, you might have to come up with a new throttle tube as well. __________________ 2009 XR650L Big Red Pig Tusk bar risers 2007 X-Moto(Jetmoto) GY250 --mods--- 15/40 sprockets UNI Pod Filter 2007 Shineray TMS 200XYi--Betsy Betsy Mods:______________________ Acerbis DHH headlight FMF Powercore pipe Uni Pod Filter
	0

01-30-2008, 06:15 PM	#3
liverchip Join Date: Nov 2006 Location: Mystery Spot Posts: 1,223	Sprocket/chain size will me an issue as well as I believe the motor comes with a 428 and the Yammy might have a 520.....Might need to get a 520 countershaft sprocket for the motor. Bruce should have them. __________________ 2009 XR650L Big Red Pig Tusk bar risers 2007 X-Moto(Jetmoto) GY250 --mods--- 15/40 sprockets UNI Pod Filter 2007 Shineray TMS 200XYi--Betsy Betsy Mods:______________________ Acerbis DHH headlight FMF Powercore pipe Uni Pod Filter
	0

01-30-2008, 06:24 PM	#6
liverchip Join Date: Nov 2006 Location: Mystery Spot Posts: 1,223	Sounds like a very do-able project! Keep us posted. __________________ 2009 XR650L Big Red Pig Tusk bar risers 2007 X-Moto(Jetmoto) GY250 --mods--- 15/40 sprockets UNI Pod Filter 2007 Shineray TMS 200XYi--Betsy Betsy Mods:______________________ Acerbis DHH headlight FMF Powercore pipe Uni Pod Filter
	0

01-30-2008, 08:40 PM	#10
warrior91 Join Date: Nov 2007 Location: N.E. Saskatchewan, Canada Posts: 679	Shim it up. __________________ '91 Yamaha Warrior- stage 2 '83 Honda ATC 70 '08 Yongjiang 125cc mx (Loncin) '08 Yongjiang 150cc atv (Jinlong)
	0

01-30-2008, 06:18 PM	#4
mebigdave Join Date: Dec 2007 Location: New Zealand Posts: 196	"Throttle assembly on the Yammy is a push/pull design" Hmm.. didn't think about that!
	0

01-30-2008, 06:21 PM	#5
mebigdave Join Date: Dec 2007 Location: New Zealand Posts: 196	I checked out the chain conversion from 428 to 520 and using the "gearing_calc.xls" speadsheet, I guess I will go with a 13T front and a 46T - 50T(STD) rear.
	0

01-30-2008, 06:43 PM	#7
mebigdave Join Date: Dec 2007 Location: New Zealand Posts: 196	Will do! I will be collecting the bike tomorrow night and the motor should arrive early next week. :wink:
	0

01-30-2008, 07:55 PM	#8
TeamCheap Join Date: Jun 2006 Location: directly under the earths sun............NOW Posts: 2,302	looks like a good / fun project. The only real problem I can see is the exhaust but I'm sure you'll get that worked out, there are enough exhaust systems out there that one should fit it easy enough. Once you get the spockets aligned perfectly and the engine mounts set it should all be down hill.
	0

01-30-2008, 08:35 PM	#9
mebigdave Join Date: Dec 2007 Location: New Zealand Posts: 196	The more I look at the photos of the bike, the more worried I get about getting the head in under the tank! I guess I'll only know once I pickup the bike and can see under the tank. Does anyone know if there is any way to mod a plactic tank?
	0

01-30-2008, 08:43 PM	#11
mebigdave Join Date: Dec 2007 Location: New Zealand Posts: 196	I'm thinking that there is not going to be enough space for the head to sit between the two lower halves of the tank?
	0

02-01-2008, 03:17 PM	#12
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	I will probably be tight, but I think you can get it in there. Allen __________________ You meet the nicest people on a Honda Clone.
	0

02-25-2008, 04:17 PM	#13
mebigdave Join Date: Dec 2007 Location: New Zealand Posts: 196	Just a little update! Over the last few weeks, I've stripped down the YZ250 and replaced the Swing arm bearings and seals, the Linkage bearing and seals, the lower shock bearing and seals and replaced the fork oil seals and dust seals. I've also spray painted most of the frame. The wheel bearings front and rear were in good condition so I did not have to replace then. I have packet every bolt and bearing with waterproof grease. I had a small number of spokes to tighten and a whole lot of greasing to do. On the swing arm, the motor had a mount that the swing arm bolt went through. Because I'm using a 169FML motor I needed to make a bush to fit in place of the motor and this also stops the swing arm from bending inward. I've added a grease nipple to the bush so that I can pump grease onto the swing arm bolt. Pictures to follow! I've finished putting it all back together and it's looking the part again. I don't have the motor in yet but this will happen over the next two weeks. It's a bit tricky as the motor almost fits in the frame but is just a bit too tall to get the tappet cover in. I am going to have to cut the frame but will still use the frame around the motor to maintain the frames strength. I'm not going to use the same china bike design with having the motor as part of the frame. I don't think the mounts will be strong enough for the frame design. Pictures to follow! I'm now down to the last little bit to do like making a battery box frame to mount inside the old YZ250 air box and I am going to put the solenoid in there to for the electric start. I am also going to have to cut the tank away at the low part to allow for the top end of the motor to fit correctly. I guess I am going to have to learn real quick to plastic weld! Funny thing is that the Intake manifold for the 163FML and the 169FML are different in the sense that the 163FML has the carburettor right behind the top end and the 169FML, the carburettor goes off at an angle! There is not going to be enough space for the kick start(thank god) so it will be electric start or push start. I've ordered the following parts to finish off the bike build: 2x Pairs of black grips. (One pair for my son's bike) 1x Throttle cable 1x Clutch lever - Complete with perch 1x Clutch cable 1x Kill switch with the push to start like on the XY200GYE + twist throttle 1x 13 tooth 520 front sprocket (JTF 328) 1x 520 chain 120 links with master link 1x Intake manifold for the XY200GYE 1x Exhaust header pipe for the XY200GYE I will still need to find a muffler at a good price to fit the "XYZ200" I'll upload pictures tonight!
	0

02-25-2008, 04:31 PM	#14
fatboy250 Join Date: Sep 2006 Location: COLUMBIA, SC Posts: 973	Dude sounds awesome! Can't wait to see how it turns out. __________________ 2008 Jonway MC-70-150 2007 Roketa DB-07B (RSM-200E) 2006 Roketa DB-07A (RSX-200E) 1995 Kawasaki Concours (ZG1000)
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02-25-2008, 06:10 PM	#15
TeamCheap Join Date: Jun 2006 Location: directly under the earths sun............NOW Posts: 2,302	I was thinking about this project the other day, cant wait to see the pics.
	0