How-To: YZ250F WR250F Top & Bottom End Rebuild

www.howtomotorcyclerepair.com...
Blog post with tool/part list, and service manuals
Full video available here:
howtomotorcyclerepair.com/yz2...
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Tools used in this video:
Motion Pro Gear Jammer 08-0427
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Motion Pro 08-0026 Flywheel Puller M27X1.0 L.H
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Torx bit set
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Motion Pro Clutch Holder Tool 08-0008
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Vessel Megadora 980 Impacta P2x100 #2 JIS Impact Screwdriver
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Milwaukee M18 Fuel ¼” impact
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Seal puller
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IR thermometer
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Tillman welding gloves
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Tusk blind bearing puller
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Pen magnet
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Titan scraper
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Super scraper
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Exacto knife
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Loctite 242
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Threebond 1184
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Blowtorch kit
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Crocus cloth
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Deadblow hammer
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Music:
Breakdown - Take the Lead by Kevin MacLeod is licensed under a Creative Commons Attribution license (creativecommons.org/licenses/...)
Source: incompetech.com/music/royalty-...
Artist: incompetech.com/

[@HTMR]

Buy full video here - howtomotorcyclerepair.com/yz250f-engine-rebuild Blog post - howtomotorcyclerepair.com/yz250frebuild/

[@408Viking]

I purchased your video and rebuilt my 2008 YZ250F. Your video was very thorough and informative. I found it easy to follow and easy to reassemble the engine, checked valve clearances, and engine is back in bike. Rebuilding carb and rear shock also and will get her started in a few days. Thanks

[@HTMR]

Thanks for the feedback!

[@pnworvandmore]

Definitely sending my 05yz250f engine too you your amazing brother

[@2uk2]

I actually start to repair motorcycle engine and i sold one of it after repair 1800£ thank you you awesome

[@mmathews1976]

Wonder if you could help... Got a 2015 yz250f, not sure what direction main crank gear and counter weight bolts are - manual does not state? Do you know if your full video is same motor?

[@HTMR]

Video will help for your year. Email me and share the service manual and I will take a look at those fasteners.

[@nathanallen5130]

Hi Matthew can you help me fugue out how to fit a 2003 yz 250f crankshaft into a 2001 yz250f?

[@delfintrujillo2067]

Can somebody tell me what that rod is that is fight in front of the crank

[@ronenfe]

I think you have to remove the springs bolts gradually, so the pressure on the pressure plate will be equal around the springs.

[@HTMR]

Yeah, that is the correct way to do it. I've never had issues.

[@hunterholman3525]

Would this work with a 01 yz250f? I cant seem to find a rebuild kit for an 01 either only 03 and up.

[@HTMR]

Yes, and you don't always need to buy a kit. Go with OEM parts: kzbin.info/www/bejne/m6LIZmyZfrOebaM

[@frankiemarchese2978]

Hey Matthew what do you use as a sealant for the cases when putting them back together? Im in the middle of doing a top end on my 05’ wr450f and noticed a slight up and down play in the left side main bearing near the flywheel. Definitely going to be splitting the cases now. Also would you recommend putting a new crank in it as well? The crank seems fine the rod has no up and down play at all. Thanks!

[@HTMR]

Threebond 1184 - look here under tools : www.howtomotorcyclerepair.com/yz250frebuild/ I'd have the crank rebuilt. Why go through all the trouble of splitting and not replacing it?

[@BramVanhautte]

How did you get your second case half on so easy? My crankshaft is not fitting in the bearing at all :p

[@richardkirkland3295]

Thank you for your help. Don't know why other videos on clutch rebuild videos don't have the clutch spring plate or as Yamaha calls it clutch spring boss they just put the clutches in it without it don't know why my yz250f has the clutch spring boss and bottom plate before clutches

[@HTMR]

Have you seen this video: kzbin.info/www/bejne/oJfPi32LZ9h4jKs

[@KincadePavich]

How different is the '01 YZ250F?

[@HTMR]

Same, I must have not listed all the years.

[@frankiemarchese2978]

Hi Matthew, do I need to go as far as cleaning the old loctite out of the threads? Will it being there not allow the new loctite to tighten up? Thanks! Might be a stupid question but its tough to get it out of the threads in the cases

[@HTMR]

Some loctite can remain.

[@tomislavhorvat7054]

Hi, I have a question about the transmission forks, I have two type C forks, both removed from yz250f 2005. One is marked 5NL 5 and the other 5NL 8 so I wonder if you know what the difference is? Are both original for that engine?

[@HTMR]

I don't know sorry. The service manual might have some info.

[@lyroncolvin5532]

Hi Mathew all the way from NZ here I've seen your videos online I have an 01 yzf250 any chance you have videos of a rebuild for one of these? Cheers lyron 👍

[@nazt8952]

There's 1 on KZbin M'bro

[@austinsober8761]

What do I need to do to get my motor shipped to you

[@frankiemarchese2978]

Hey again Matthew. How important to you is the cross hatch when coming to installing a new piston/rings? My cylinder has slight cross hatch in it but does not cover the entire cylinder. It is nikisil and heard that theyre very delicate, would it be worth running a flex hone 320 grit in there to get the cross hatch back? Thanks!

[@HTMR]

Take wd-40 and green scotch brite to de-glaze the cylinder. Wash really well with hot soapy water. This is all assuming it measures in spec. The flex hone material is not hard enough for nikasil.

[@frankiemarchese2978]

Im scared to run scotch brite through it lol it wouldnt take any material off? I dont know the exact clearances but it ran good before i took it apart

[@HTMR]

@@frankiemarchese2978 Nikasil is super hard, you won't damage it.

[@fernandosuvillaga9848]

Fast foward to 4.15

[@danklovell1133]

if i purchased this video would it give me enough knowledge to completely rebuild my 2012 WR250F? i was riding it and the rear tire just locked up and the kickstarter was stuck. i took it to a shop and told me they drained the oil only to find 2 ounces left and they said some type of rod or pin came out. they also the cases were grenaded and the entire engine was basically screwed but they’d fix it for $5k. i’m mechanically inclined and would love to get into a project like this. your input would be very helpful.

[@HTMR]

Yes

[@yamaha4447]

hello, crankshaft with yz250f 2004 fit for wr450f 2003?

[@HTMR]

Not sure sorry.

[@ATKX]

I’ve always thought there was a gasket where the case splits, is there not? I only see you putting gasket behind the clutch? I have a oil leaking that’s coming from the bottom of the engine and thought it was from the very middle part, apparently might be from the clutch side?

[@HTMR]

Some models use a gasket, others use sealant.

[@frankiemarchese2978]

Hey Matthew, sorry for all these questions I wanted to get your opinion on something. I have all the new bearings for my wr450f bottom end, I noticed one of the transmission bearings is hard to spin. Its not notchy or catching up on anything, it just has a lot of resistance. Is this normal, have you ever ran into the same thing on a bearing? I already ordered another one because i dont feel comfortable with it and its also cheap enough. All oem too by the way. Thanks!

[@HTMR]

Just replace the bearing and move on. No sense in reusing a questionable 10-20 part.

[@frankiemarchese2978]

Ill just get another new one. The one i took out of the bike was hard to spin also so i thought maybe it was normal. Ill buy one more to see if i really got a defected one. Thanks

[@SnipingWithSkillz]

Since yamahas dont have crank seals how is it possible theres no air leak, or pressure at the main bearings from the piston

[@HTMR]

Majority of 4 stroke/cylce engines do not have crank seals internally to combat air movement from piston.

[@richardkirkland3295]

Can you pull the crank out without pulling transmission inside the case?

[@HTMR]

You have to split the cases to remove the crank, however the trans can stay in place. LH side must be down on workbench.

[@richardkirkland3295]

Thanks for the help

[@frankiemarchese2978]

Hi Matthew i have a question. @11:07 you said it can be taken off with an air gun? Without a gear holder? Im at this stage now and dont have a gear holder but have an air gun. Thanks!

[@HTMR]

Yes, just put some rags around the rod so it doesn't slap around. Hold fly with your hand.

[@frankiemarchese2978]

Thank you! Wasnt sure if i needed to get a sheave holder also, but i figured an impact will do the job. Also is that nut reverse thread? Or is the puller the only thing that’s reverse threaded. Thanks!

[@frankiemarchese2978]

Nevermind i just watched it again and saw you take it off regularly

[@frankiemarchese2978]

Also @16:18, did you have to put a new oring in there as well as the too of the case for the coolant passageways? The manual has the “new” symbol next to the orings so im just seeing if you really need new ones. I might just buy a viton oring kit with all different sizes

[@HTMR]

Yes, and buy OEM. Not worth guessing the size.

[@frankiemarchese2978]

Bikebandit doesnt have those o rings under a part # i looked everywhere. Unfortunately i might have to go with a non oem viton o ring. I would reuse them but would hate to take off the cylinder just for that lol

[@frankiemarchese2978]

Okay so the 2005 yz250f has the part number on bikebandit but not my 2005 wr450f lol im gunna see if the 2005 yz450f has a part number because that has to be the same size o ring

[@frankiemarchese2978]

I found the part # for my 05 wr450f lol it was under waterpump instead of crankcase cover like the 250f

[@GregHuston]

Is a Case Splitter not necessary? I have all the tools except the clutch holder and case splitter. I've done top ends before; but am about to tackle a bottom end on my 2006 YZ250F to swap the Gear Box for a WR gear box. Most likely I will buy the video once I have all my parts and tools.

[@HTMR]

No splitter needed on this model. Let me know if you have any other Q's.

[@frankiemarchese2978]

Hi again Matthew. I just got all my bearings out of my 2005 wr450f bottom end. Btw the oven trick worked great. I have a question about the new bearings being installed. Is the lettering supposed to be facing me as i install them? Or are they different from bearing to bearing? For example my main bearings seemed like they were installed backwards (lettering facing down). Theres a lip on one side so i assume theyre meant to be put it one way only. Would you be able to know the answer to this? Thanks, i can upload a video if needed

[@frankiemarchese2978]

Also thise bearings with a seal on one side, is the seal facing out or down in the case? Thanks!

[@HTMR]

@@frankiemarchese2978 If there is a bearing oreintation, the service manual will call it out. Otherwise it does not matter. If there is a lip for retainer, then it must be installed the correct way. Do you have the service manual? They usually have a cross section of seal orientation.

[@frankiemarchese2978]

Yes im looking through it now. In chapter 1 under “important information” it says to install bearings and oil seals with their manufacturer marks or numbers facing outword. Im shocked that the main bearings were in there the wrong way lol at least i think they were since the letters werent facing out. But theres one transmission bearing that is sealed on one side, and the sealed side has the letters on it. I thought the sealed side of the bearing was supposed to face down lol thats where im getting confused. Im gunna put the sealed side down on that one when the time comes. Just waiting on all the parts. Thanks!

[@frankiemarchese2978]

Okay so i was looking at the cases again and i think they were in there the right way. The lip on the one side of the bearing i believe is for the retainers. Kinda makes sense now.

[@bogdangoaga9088]

how many nm have you tightened the screws on the clutch cover?

[@HTMR]

I have the service manuals on my site.

[@bogdangoaga9088]

Dank

[@jessechmiel9091]

I just purchased the video off of your website on gum road. Where is the email so I can contact you I have a question?

[@HTMR]

Reply to the gumroad emails you received or contact me here: howtomotorcyclerepair.com/contact/

[@David20161009]

Where are you located. I'm thinking about buying a locked up yz250f and wanna get the motor fully rebuilt

[@HTMR]

Chicago area.

[@markclay7136]

How do i get a hard copy dvd of this whole video?

[@HTMR]

I don't sell DVD's. Buy the video here and watch instantly: gumroad.com/l/yz250f

[@beaubyatt2422]

Would a yz450f be much different? 2009

[@HTMR]

It's 90% the same. This video and service manual for your model will help you out big time.

[@stevenharris2973]

Coronas are a must when working on my bike

[@HTMR]

Yup.

[@peytonstevens3466]

Hey man I have an 08 YZ250f i recently got last year and earlier in 2019 I was riding and the bolt to the oil popped off and I lost all the oil locking up the entire bottom end. I’d love to send you the engine. I have all the new parts but need someone to put her together cuz I don’t know shit about engines 😂 the engine is completely torn down btw from scratch basically...

[@HTMR]

I'm not accepting service work at the moment. Buy the video it walks you through every step.

[@wayneboehm8139]

How has that beer been sitting 😎😆

[@HTMR]

Empty....need a refill.

[@Dee_p_sa-ku]

Beer funding is best😇

[@datwestboi18]

Hey do you have a shop where u fix other people bikes or just your buddy’s???

[@HTMR]

I repair bikes on a part time basis from my home garage. I'm near Chicago.

[@datwestboi18]

MatthewMCRepair i have a 2006 YZ250f and a kx 250 i would love for u to rebuild if u up to it!!???

[@HTMR]

Steven, I have detailed videos on both those models, why not rebuild them yourself? I'm pretty swamped right now.

[@datwestboi18]

MatthewMCRepair i just don’t think i can get it, i can break it down but not back together lol. That’s y I’m willing to pay upfront to get the job done

[@HTMR]

My video makes it easy. Just give it a shot.

[@nicholascrosswell1863]

Hey man are yz250f shit the 2007 model or they a good bike to have.

[@HTMR]

They are fine.

[@nicholascrosswell1863]

Cheers man

[@frankiemarchese2978]

Hi Matthew, is there any bolts you use red loctite on in the engine? Or is it all blue medium strength loctite.

[@HTMR]

I believe only blue. Double check with service manual since it has been a while for me.

[@frankiemarchese2978]

Yeah it states to use loctite on certain bolts but doesnt say red or blue. Ill have to go through it again, thanks!

[@HTMR]

@@frankiemarchese2978 Blue is fine.

[@lakennethwhaley7821]

New here how much do you charge for a full rebuild

[@HTMR]

I'm not accepting service work at this time.

[@eggsandbread1]

could do with speeding up how to take it apart and slowing down how to actually rebuild it

[@nathangregory9002]

Exactly

[@michaelpresey2273]

It's because he sell the videos for like 30$ the link is in the description

[@seab7772]

How hard is a rebuild for your typical somewhat mechanical person?

[@HTMR]

Easy when there is a video that walks you through it step by step. I've had tons of first timers complete rebuilds from my vids.

[@johnpaulstez]

Did you Sweat the crank bearing into the case or was it the crank into the crank bearing I kind of missed it

[@HTMR]

I heat the case on my BBQ grill until it reaches 200°. Bearings slide right in. I froze the crank and heated the bearing a bit to drop it into the LH side. Slip fit for RH side. Watch this video: kzbin.info/www/bejne/iF7HZoRoibd_rKs

[@isakhansen2152]

Hello! I was wondering if you have all the video slow and when you talking (without music and speed up). If I can get it it would be so awesome! You can get my gmail if you want. Thanks!

[@gogorome456]

Bro you have to pay for it

[@dannym.6346]

Would this work for a 2002 yz250f?

[@HTMR]

Yes.

[@GUNNERJOE39]

Does this cover a 2005????

[@HTMR]

Yes.

[@714858]

Were is the top end in this video

[@HTMR]

Top end footage is from another engine (in frame) and included with video purchase.

[@rocklives12]

u should really crack the bults buy hand first and undo them opposite from reach other stop distorting the plates. just the way I was thought.

[@HTMR]

Never had an issue this way.

[@rocklives12]

MatthewMCRepair Doesn't mean it's the correct way. But keep up the good videos

[@jayfinesse8228]

Can really see what u do it's on speed

[@HTMR]

Full video is regular speed and over 5hrs of footage: gum.co/yz250f

[@johnnyboy1543]

You lost me on paying….

[@EastCoastOffroadSA]

Why don't you just show the whole vid now we have to pay for it

[@HTMR]

Because it is 5hrs long and cheaper that a shop.

[@ericm1430]

Available for purchase, you cant be serious? You're using your youtube account with 80k subs as advertising on basic engine work. you should be grateful you have subs from this content nevermind selling it.

[@HTMR]

Good luck dude.

[@codya990]

The fact that this guy wants you to basically pay for a full engine rebuild guide, but yet doesn't even know basic maintenance practices such as removed bolts in a crisscross pattern. For example removing the clutch pack he did it in a circle which results in warping of the clutch plates. Then on top of that probably reinstalled the same clutch pack. Not a big fan of this guys work he cuts a lot of corners.

[@HTMR]

Trust me, the plates are not going to warp. If so, prove it with your own videos.

[@rodneyfinley6367]

Rip off

[@HTMR]

You should go to the dealer and pay $400 in labor.

[@rodneyfinley6367]

@@HTMR not when there is other free videos out there