Yamaha TZR250 refresh

[SoCal250]

I let my TZR250 sit for way too long (we're talking years), so I'm currently going through the recommissioning process...
The "To Do List" is quite long:

• Clean & rebuild carbs
• Replace fuel hoses
• Replace in-line fuel filter
• Add in-line manual fuel shut-off?
• Delete carb de-icing circuit
• Rebuild petcock
• Flush fuel tank
• Replace bad temp sending unit
• Flush cooling system and check
• Change trans oil
• Check & replace spark plugs
• Replace chain
• Replace front & rear tires
• Rebuild rear brake master & caliper
• Rebuild front brake master & calipers
• Replace battery
• Clean & detail

Carbs have been thoroughly cleaned in the ultrasonic and rebuilt with all new brass.





Replaced all fuel hoses.
Bypassed the carburetor de-icing circuit.

[SoCal250]

New tires and chain

[SoCal250]

Currently working on brakes.
Rear master is done, caliper will be completed today, then I'll move to the front.

[SoCal250]

The mailman just dropped some more needed bits. The front master kit arrived just in time for the rebuild

[m in sc]

nice!!!

[pdxjim]

Have I mentioned how much I regret selling mine?

[SoCal250]

Have I mentioned how much I regret selling mine?

Yeah, you should have never let that one slip through your fingers.

[SoCal250]

Progress!
Got the caliper rebuilt and the rear brake system installed on the bike. Just need to fill and bleed. Pistons were OK and everything cleaned up well even though it was pretty grimy and crusty in there.

The "To Do List"

• Clean & rebuild carbs
• Replace fuel hoses
• Replace in-line fuel filter
• Add in-line manual fuel shut-off?
• Delete carb de-icing circuit
• Rebuild petcock
• Flush fuel tank
• Replace bad temp sending unit
• Flush cooling system and check
• Change trans oil
• Check & replace spark plugs
• Replace chain
• Replace front tire & rear tire
• Rebuild rear brake master & caliper
• Rebuild front brake master & calipers
• Replace battery Charged, seems to be OK
• Clean & detail

[85RZwade]

Go get 'em Russ, that's awesome 

[NoRiders]

Excellent work

[SoCal250]

Got the caliper rebuilt and the rear brake system installed on the bike. Just need to fill and bleed. Pistons were OK and everything cleaned up well even though it was pretty grimy and crusty in there.

The rear brake work that was completed Friday.

[SoCal250]

Currently working on the front. Made some progress yesterday.
Removed the whole system from the bike. The master has been disassembled and run through the ultrasonic and is now awaiting reassembly with the rebuild kit. Brake lines have been flushed.
Today's task is master reassembly, then breaking down the calipers and cleaning them up in preparation for assembly with new seal kits.

[SoCal250]

I've run into several road blocks:
1) The front master is cleaned, rebuilt and ready to go back on, then I realized I hadn't removed the reservoir elbow to clean under it. It's not being cooperative. (Started a thread in Turning Wrenches about it.)
2) Several pistons are stuck in the front calipers. All outboard ones -- two on one side and one on the other. I've scrubbed around the outside edge of the bores to clean up the gunk but can't get them to budge. Even tried rotating and pulling with tiny vice-grips with a towel on the very edge of the exposed piston (outside the seal area) and no movement. They're now soaking in PB Blaster.
I think I'm going to have to get creative with some small C-clamps and pieces of rubber sheet to seal the crossover ports, and a larger C-clamp for the pistons. And then hit it with air again on the separated halves.

[85RZwade]

Russ, try these:



They're just big-ass external snap ring pliers that every bike tech I've known used for caliper pistons. They're serrated (knurled?) on the tips and you can get a good bite on the inside diameter of the pistons.



I think I got mine from Motion Pro

[busa1300]

Looks like fun so far. It appears you have a SP/SPR swingarm on there. Are your forks fully adjustable by chance also?