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1:11 YZ250F 2019-2023 Full Motor Rebuild (Part 4) Finally done! Run this Yamaha through heat cycles — Transcript

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0:01Welcome back to the shop, guys. We're
0:02going to get this YZ250F up and running
0:05today. We're going to finish this job
0:06today. We're going to hear it start up.
0:09I still need to adjust the valves and
0:13install the cylinder head,
0:15button everything up,
0:17fire her up. So, let's get started.
0:22All right, let's go and get these valves
0:23adjusted.
0:28Pop these out.
0:30Now, this is going to be This is brand
0:31new valves and a brand new cylinder head
0:34with brand new camshafts.
0:39Come on.
0:43There we go.
0:46All right.
0:48Got the intake cam right here. There's
0:50the intake side.
0:57I'm not going to worry about putting
0:59these on. I'm going to put the cam caps
1:01on just for checking the valves
1:03um because
1:06if you look closely here,
1:09I don't know if you can get it on camera
1:11get it on camera here. You see that
1:12little piece right there how it matches,
1:14that little marking? There's a marking
1:16on the heads where it matches.
1:18So, I'm just going to line the cam the
1:20little groove on the camshaft bearing to
1:23that little marking and that's good
1:24enough for checking the valves.
1:43Okay.
1:45Drop all these in.
2:08There we go.
2:12Okay, they spin nice and freely, so
2:13that's good.
2:16Break out the feeler gauge here and
2:17break out the manual and see what the
2:19specs are for them.
2:22Okay, then I'm going to specs right from
2:24the manual. We're going to start with
2:25the exhaust here. It says I'm going I'm
2:27going to use inches.
2:29And uh let's see 67 to 94. So, I'm going
2:32to say 7,000ths to 9,000ths. We're going
2:35to want it somewhere in that range. I'm
2:36just kind of rounding them
2:38rounding them into the tighter end, 7 to
2:409. All right.
2:44Break out the old feeler gauge.
2:47Start with the seven here.
2:52That one's a little too tight.
2:55And that one's a little too tight, so
2:56we're going to have to loosen them up a
2:58little bit. If I can't get a seven in
3:00there, let's see if six fits.
3:03I can get the six in on this one, but
3:04not on that one. Let's see if a five
3:06fits on this one.
3:07I can get a five in. So, these are just
3:09a little bit on the tight side, which
3:11means I'm going to have to put a smaller
3:13shim in it. Let me put a little negative
3:14sign here and there.
3:17That's going to let me know that we need
3:18to put a smaller shim.
3:20There we go. Change my camera angle a
3:21little bit get get you guys up in here a
3:23little bit better to see what I'm doing.
3:27Okay, the intake
3:29point or I mean
3:3147,000ths to 75,000ths. So, we're going
3:33to say
3:34uh 4,000ths to uh 7,000ths. Four to
3:38seven. Let's see what we got.
3:41Again, I'm rounding them out on the
3:42tighter end.
3:44Let's start
3:47with the four.
3:50Can't get the four in. Oh, I can get the
3:52four in there on that one.
3:54Let's go to five on that one. Can get
3:55the five in.
3:57Six.
3:58Can get the six in.
4:01Seven.
4:03Can get the seven in. That one's
4:04probably going to need to be a little
4:05tighter.
4:06Eight. Can get the eight in.
4:09Nine.
4:11Let me show you what I'm doing here
4:12since you really can't see. I'm just
4:14sliding right in here
4:16like this between the um
4:19the camshaft lobe and the um
4:23the camshaft lobe
4:26and the cam bucket.
4:28You obviously want to make sure it's on
4:30the flat side of the cam. But anyway, I
4:32can get the
4:33the nine in there.
4:34That clearly needs to be tighter.
4:37Heck, I can get the 10 in there barely,
4:39but I can. So, we know that one needs to
4:40be tighter, so I'm going to have to go
4:41with a bigger
4:43shim on that one.
4:45So, I'll put a plus there.
4:48Let's check this one over here. So,
4:52let me look back at this again.
4:54Remember the intake was I said five to
4:58five to seven.
5:02Try the five again. Nope.
5:04Four.
5:05Nope.
5:06Three.
5:08Nope.
5:11Two and a half. No, that one's pretty
5:13tight.
5:14Two.
5:16All right. That one's just going to need
5:17a
5:19a smaller shim, period.
5:25There we go.
5:28Now, we know that one's really tight.
5:31It's really tight. Like I know these
5:33just need a little to be a little bit
5:34smaller.
5:35This one just needs to be a little bit
5:37bigger.
5:38But this one right here, it needs to be
5:40a lot smaller. So, I'm going to put two
5:43negative signs there just let me know
5:45might want to go a little extreme on
5:46that one.
5:53So, I'm going to swap all these cam
5:54caps.
6:08These things can sometimes be stubborn.
6:15Start with the one that needs a lot of
6:17work.
6:19Measure that one out.
6:261.85 mm. It needs to be smaller.
6:30So, let me see.
6:32And a lot smaller at that.
6:39I'm just going to go crazy with it. I'm
6:41going to throw this one six 1.6 in.
6:47Let's just see.
6:53Got to get that in there just right
6:55before it drops in. Oh, there's a piece
6:56of cloth stuck on.
7:00There we go.
7:04Okay, we know this one needs to be
7:05bigger.
7:11Wow, that's crazy the difference between
7:12the two, but okay.
7:141.83.
7:17And it needs to be bigger, so we're
7:18going to try
7:23not a lot bigger, just a little bit.
7:29We'll start with that.
7:32See where that takes us.
7:37Okay, the exhaust here needs to be
7:39smaller.
7:44Come on.
7:45All right.
7:48Uh
7:53Little tap right here on the edge.
7:57That always gets them to pop right up
7:59off of there.
8:07190 needs to be a little smaller.
8:11So,
8:17see what we can find.
8:20That's a lot smaller.
8:26185, let's do that.
8:41Okay.
8:50190 again.
8:55And it needs to be smaller.
9:01Start there.
9:12All right.
9:15Let's pop these suckers back on.
9:18Line Again, I'm going to line up
9:23I'm going to line up that keyway right
9:26there with the marking on the case.
9:28That's where it's going to be at when we
9:31bolt it down on the bike.
9:44All right, let me put the bolts back in.
9:46Okay, let's do it again.
9:48Intake five to seven. Start with the
9:51five here.
9:54I can get the five in there. I can get
9:56the five in there. They might actually
9:57be too loose.
9:59Now, let me try the
10:02I'm sorry.
10:04They might be good. Six, I can get the
10:06six in. I can get the six in. As long as
10:08I can't get the seven in, we're good. I
10:10can get the seven in. I can get the
10:11seven in. Okay, they're
10:13They're
10:14They're a little too loose now. I can
10:16barely get the eight in. I can barely
10:18get the eight in. They're a little too
10:20loose now. So, we're we're going to have
10:22to make them uh both a little bit
10:24bigger.
10:26Or that one's still loose, I should say.
10:28So, let me go ahead and make these a
10:29plus mark right there.
10:33But they both just need to be just a
10:34little bit bigger, the valve shim. Let's
10:36go ahead and try the exhaust side.
10:38Supposed to be
10:427 to 9.
10:47Let's try the seven here.
10:53I can get the seven in. It feels good.
10:56Just a little bit of friction. Can't get
10:58the eight in.
10:59Can't get the eight in. That is good.
11:01We're going to leave it right right
11:02there.
11:03I can get the seven in.
11:06Oop.
11:07With the mildest amount of friction.
11:10Let's try the six.
11:13Yep.
11:16We're good. We're going to leave that
11:18right there.
11:19That's going to be good for the exhaust.
11:21So, we're good there.
11:23So, uh I need to erase these marks right
11:25here or I'll just put a circle around
11:27them.
11:28Lets me know that they're good.
11:31All right.
11:32Okay.
11:37187. Oop, not I don't want to stick that
11:40one back in there.
11:42Find something bigger than that.
11:45193.
11:48Let me flip that one over.
11:57Make sure that surface is really nice
11:58and clean in there.
12:03All right.
12:11I don't like the way that one's sitting
12:13in there. I'm going to get a different
12:14one.
12:22All right, this one's 191. Let's Let's
12:24go there.
12:26There we go. I like it when they
12:28kind of pop into place like that.
12:39Mhm, mhm, push it back. I got cockeyed
12:41in there.
12:43There it is.
12:49Okay, I'll be right back.
12:52Try 191 here. They're actually working
12:54their way back towards equal, and that's
12:56fine. That's what I want to see. I want
12:58to see them on a new setup like this, I
13:00want to see them
13:01be uh
13:03pretty equal.
13:04That lets me know every everything's
13:06good. I don't want to see one that's way
13:08You got I got new valves and new head.
13:12It's nice to see the valve shims that
13:14requirements for it very close.
13:19So, let's see.
13:20Let me put these in.
13:21Okay, let's try again.
13:24And take
13:26I'm going to start Make sure I can't get
13:27an eight in there.
13:29Remember, it's
13:35Okay, make sure I can't get an eight in
13:36there. That means we just got to go
13:37bigger.
13:38I can get an eight in there. Can't get
13:40an eight in that one. So, that's good.
13:42But I clearly can get an eight in this
13:44one. So, we actually got to go bigger in
13:46that one.
13:48What I'll do before I go bigger is I'll
13:50pour water in it. Just make sure it
13:51didn't get cracked open and something,
13:54you know, a piece of dust or whatever
13:56while shimming it got up underneath the
13:58valve. The valve got cracked open.
14:00Okay. So, let's see if this one's good.
14:03We know we got to make this one bigger
14:05still. Uh let's see if this one's good.
14:07So, it's going to be five, six, or
14:10seven. So, let's try the seven out.
14:16Okay, I can get the seven in there.
14:19That's good.
14:20Uh let me go back to the eight again.
14:22Double-check that I can't get the eight
14:23in there. As long as I can't get the
14:24eight in there, we'll call it good.
14:30Let's see.
14:33Nope.
14:34I cannot get that eight in there. So,
14:36this one's good. Try the seven one more
14:38time. I like to double-triple-check my
14:40work. Can't get the eight in there.
14:42Let's try the seven again. Yes, I can
14:43get the seven in there. This one's good.
14:45I'm going to wipe that up Circle that.
14:47Where's my marker?
14:51This one's good. We do need to make this
14:52one right here just a little bit bigger.
14:54So, let me do that.
15:06Okay, where was this one at?
15:10190. That one was at 191. I'm actually
15:12get 191 89. They're going to be pretty
15:15similar. That's going to be good.
15:17Let me find a bigger shim for this.
15:19About 192. If I squeeze it hard enough,
15:22I can get it to 191. Let's give that a
15:23shot.
15:25Okay, let's try. Pop a seven in here. I
15:27can get the seven in there.
15:30See about the eight. If I can get the
15:31eight in there, I'm just going to have
15:32to go bigger.
15:35Yes, I can.
15:36Let me pour water in it. Make sure she's
15:38still holding. Put it on that valve.
15:40Make sure no dust got in it.
15:43Cuz that will definitely make it where
15:44you have to keep putting a bigger shim
15:46in it.
15:48It's looking good. Let me pour that out,
15:50blow that out, and we'll keep working.
15:53Okay.
15:57196.
15:59195. Let's try that out.
16:08There we go. Sometimes they don't fall
16:09in there square. I just push that bucket
16:11on it real firmly. That squares it out.
16:13You'll hear it pop when it does that.
16:18Let's put this back on and test it.
16:20Still just a hair bit too loose.
16:24All right. Um
16:27I got a two a 2-mm one here. I'm going
16:29to pop that one in. That's got to do it.
16:32Holy cow, about freaking time. All
16:35right, that did the tricks. We have a
16:37little bit of you know, this one is
16:39about 1.91. This one's about two. So,
16:44you know, they're close enough. That's
16:46good enough for me. They're not like
16:47real far out from each other for all new
16:50setup. We're good.
16:51Okay, I'm just going to go ahead and
16:52double-check them one more time off
16:54camera, all of them one more time, and
16:57uh then we're going to go ahead start
16:58installing this. All right, we are
17:00getting there. Let's go ahead and
17:03pull this off.
17:06I had that there, you know, just to keep
17:08dust and stuff from falling on the
17:10cylinder, piston, and stuff while
17:11setting it in.
17:13I already had these roll pins in here.
17:16Oh, I got my magnet. We need to pull the
17:18timing chain out of there.
17:25There it is.
17:28Okay, I'm going to set the timing chain
17:30right over the edge here real gently.
17:33There we go.
17:36Slide this
17:38front guide. You want to make sure this
17:39tip right here goes into its seat down
17:42there in the bottom. If you look down
17:44as you're sliding it which I'm doing
17:46right now.
17:47All right, now that we have that in
17:48there,
17:49I'm going to go ahead and just gently
17:51drop this back in the place like this.
17:55Try to push that in as I do it a little
17:57bit cuz that's going to help us slide
17:58the cylinder head on.
18:00Okay, let me take my gloves off
18:03because I want to check the surface
18:05of the cylinder. Make sure there's just
18:07no dust on it or anything.
18:11With my bare hand.
18:13That's nice thing about wearing gloves
18:15is when you take your when you take your
18:17uh gloves off, your hands are so clean.
18:20And they're nice and damp and soft from
18:22being in the gloves. And I have real
18:24good feel. And uh
18:27I can make sure all that stuff's clean.
18:28Let me go get the head gasket.
18:30Here we go.
18:42All right, it's time to set that
18:44cylinder head on. Here we go.
18:46Before I do that, because I have OCD,
18:49I'm going to verify that I have the uh
18:51piston in the correct way one more time.
18:53Smaller exhaust valves on the side back
18:55where the exhaust is at. Bigger intake
18:57for this motor cuz it is a backwards
18:58motor. Bigger intake on the front where
19:01the intake's at. It's looking good.
19:05And then I'll double-check the bottom of
19:07this. Make sure there's no dust, lint,
19:09anything like that.
19:12Everything's looking good. Isn't she
19:14beautiful?
19:15Put it on.
19:51Yes, sir.
19:56Come on, guys.
19:58You know I'm in here making a video.
20:00You know it.
20:02Yeah.
20:03Don't be trying to sneak up behind.
20:07Nope. Nope. Nope. Nope.
20:09All right. Hopefully it doesn't sneak up
20:11behind me and get me in the ankles.
20:14Okay, each head bolt I oil the washer
20:17and also the threads. Just put some oil
20:19on it. Now, there is one head bolt that
20:21is a little bit longer. That's this one
20:23right here than the other three. That
20:25one goes in the right
20:27side of the bike on the rear. Let me get
20:30the other three now.
20:32Now that I got that one out of the way.
20:52Okay, I got to use my little
20:54cordless drill with the drive set just
20:56to do the twisting for me till these
20:58bottomed out.
21:00I'm already going to start the
21:01crisscross pattern.
21:14There we go.
21:17Okay, let's go ahead and look up the
21:18torque specs.
21:20Well, first off the sequences, that's
21:22the front. You see it says front forward
21:24right there. Sequence is the left rear
21:26is number one.
21:28And then number two is right front. Then
21:31number three is left front. Number four
21:34is right rear. So, remember that. We're
21:36going to do that zigzag process right
21:39there as it says right right here to do.
21:42Um
21:43Now, what do we need to torque it to?
21:45These are funny. These torque to yield.
21:47So, first we're going to have to torque
21:48them to 22 ft lbs. Then loosen up one at
21:51a time, re-oil it, and put it back in at
21:5411 ft lbs. And then put a mark on it and
21:57then do a whole sequence. See, they show
22:00us marking the top of the bolt and then
22:02doing a whole sequence here, but I'll
22:03show you this as we go along.
22:05Like I said, I'll show you as we go
22:07along, but it basically will have us
22:08after we mark the bolt or have a have us
22:11turn it 60° each one.
22:14And then go back through and do another
22:1660° as it points out somewhere over here
22:20for a total of uh
22:23Where is it? A total of 120°. I know I
22:26saw it somewhere here.
22:2960 There it is. 60 + 60 for a total of
22:32120°.
22:34So, let's start this process.
22:36All right, I have my torque wrench set
22:38to 22 lbs. It says to do this part in
22:41two to three sequences.
22:44Meaning don't just torque the first one
22:46right to 22 lbs, right?
22:49I'm not even setting torque wrench for
22:50this part the first one. I'm just going
22:51to tighten it till I feel it bottom out.
22:55There we go.
22:56The whole idea here is just that that
22:57way you don't pinch one side of the
22:59gasket like the first bolt. You put it
23:01right to 22 and you just pinch it hard.
23:04What I'm doing is I'm just turning each
23:05one till I feel it bottom out. Of
23:06course, doing the cross pattern that I
23:08showed you just a minute ago.
23:20Okay, now I'll put them to 22 lbs and
23:22stop there for now.
23:26There we go.
23:32All right.
23:36All right.
23:42Okay.
23:45Now I have my torque wrench set to 11 ft
23:48lbs.
23:50Let me loosen up the first one here
23:52and remove it.
24:02Just following their directions.
24:05I'll let the washer stay down there. I'm
24:07not going to pull it out. As long as I'm
24:08nice and careful, it'll stay right in
24:09place.
24:15Re-oil it just like they said to do.
24:19Here we go.
24:27I mean, actually the manual says to use
24:28some type of grease or whatever, but oil
24:30is just as well.
24:34Don't worry. I've done a million of
24:36these.
24:40That was 11, but let me I went kind of
24:42quick there. Let me loosen up a hair.
24:43You want to get it right on 11 if you
24:45can.
24:58There we go. That's 11.
25:01All right.
25:02And the next one. Now, I started on the
25:04right rear. Now, I'm doing the
25:06the left front.
25:19This one the washer is stuck on it.
25:20That's fine.
25:42And torque this one right to 11.
26:00There it is. Heard it click.
26:02All right. Now, the right front.
26:19And it mentions doing it It It just like
26:21this. Of course,
26:23download the manual, read it for
26:25yourself.
26:26But it mentions doing it just like this,
26:28one at a time.
26:46Okay, same thing. Put this one right to
26:4811.
27:01There it is.
27:06Let me loosen this one up.
27:11Now, I'm doing the right rear.
27:47And torque it right to 11.
28:02Okay, now I'm just going to go back
28:03through and make sure they all click
28:05right at 11.
28:08Yep.
28:12Got a little more out of that one.
28:13That's fine.
28:18Yep.
28:23All right, we're good.
28:30Going to take a Sharpie,
28:32put a mark on each head bolt. I'll show
28:33you in a minute what what I'm doing
28:35here. I'll put the camera down here and
28:36show you.
28:59All right.
29:01If you look down here,
29:06right here, I put a Sharpie on each one
29:09of the head bolts on the front side of
29:11the bike.
29:13Each one. And that way when we turn it,
29:15we can do the whole 60° and another 60°
29:19turn. So, let's do that.
29:23Okay, I'm going to do the first round of
29:2460°.
29:33Here we go.
29:35Of course, using the same cross pattern,
29:38starting with the left rear and then the
29:39right front.
29:41Then the left front.
29:46Then the right rear.
29:52Okay.
29:53Going to do it again, another 60° of a
29:54turn.
30:19Okay.
30:28I have my torque wrench set at 30 lb. I
30:31want to make sure we at least reach
30:32that. If we don't,
30:36I would be a little concerned and see
30:38what's going on.
30:48I think that's it. Let me show you what
30:50we got.
30:58Remember the manual shows us starting
31:02right here and doing a 60° to right
31:04there first round. And then from there
31:06another 60° to get right here.
31:09So, let's see where we're at.
31:19If you look down in there,
31:23see where the mark's at now?
31:26And that one over here,
31:29right there.
31:31Get the camera light on it right there.
31:33I believe I have them all at the 60 or
31:35120° mark. So, we should be good.
31:41Beavis,
31:43what are you doing?
31:45Don't sneak up on me.
31:47All right, here we go. I can tighten
31:49this up now.
31:51There we go.
31:55I have his girlfriend right behind me.
31:57That's why he's over here.
31:59Thinks I'm trying to steal his chick.
32:02Now he's sneaking up to my right side. I
32:04don't like that.
32:07Hey.
32:08Don't you Don't you try anything funky.
32:13Okay, let me get a wrench and
32:14Well, let me put this one on by finger
32:16first and I'll get a wrench to tighten
32:17these up.
32:21All right.
32:22There's torque specs for these, but you
32:24know,
32:25use a regular wrench. Just don't strip
32:27it out. That's all. Don't be a fool.
32:28You'll be okay.
32:33All right, there we go.
32:35Okay, I went ahead and reattached the
32:36starter power wire right there.
32:41Okay, let me go ahead and remove these
32:42covers here.
32:46There we go.
32:53We're going to set it in top dead center
32:55and um
32:57put the camshafts on in there.
33:01Okay, I'm going to grab the timing chain
33:03with the magnet and pull it back out.
33:05You do never want to spin the motor with
33:07that thing down there. It'll just get
33:08kinked up.
33:10All right, before I get started, I'm
33:12going to do one full rotation on the
33:13bike as I hold the timing chain up just
33:15to make sure it's not kinked up or
33:17anything down there. And I'm looking
33:19down here
33:20for the top dead center timing mark.
33:22Now, I'll show you what that looks like
33:24in a minute when I
33:25get the camera in there with my head.
33:30There we go. By the way, the motor
33:31always spins um
33:34counterclockwise from here. So, it's It
33:36spins the same direction the rear wheel
33:38spins when the bike is going forward.
33:40Let me just hang that over here.
33:44I'm going to verify that that's actually
33:46top dead center not only by the mark,
33:47but I'm going to take this long
33:48extension and slide it into the spark
33:51plug hole here nice and gently on top of
33:53the piston.
33:56And then as I
33:58Oh, I can't Camera's bobbing around
34:00there.
34:01As I hold the timing chain up, I'll be
34:03able to look at the top of the extension
34:04here. You're probably not going to see
34:05it on camera, but I can see it. And I'm
34:07going to go
34:08one way.
34:10There it goes. Went all the way in the
34:12hole.
34:16Okay.
34:20All right, so that should be I went
34:21backwards a little bit. It's okay to go
34:23backwards a little bit, but what you'll
34:24hear when you go backwards is you will
34:26hear the starter motor spin because the
34:29starter clutch is a one-way clutch and
34:31it's designed so once the motor starts
34:33up, it releases from the starter. So,
34:35you'll hear like a
34:36when you go backwards.
34:39Okay, let me pull that out. I know we
34:42have top dead center. I verified it
34:43there, but let me show you what that
34:44mark looks like.
34:47Okay, it may be difficult to see, but
34:48there's a little triangle
34:50um
34:54right there on the stator.
34:58Let me see if I get the camera on it
34:59again.
35:05See that triangle in there? And it
35:07points right to that little slit that's
35:10right there. And that's when you know
35:12you have it at top dead center. Now, if
35:13you having a hard time finding that
35:14triangle, do like I did, put a extension
35:17up in the spark plug on top of the
35:19piston, hold the timing chain up, and
35:21spin the motor until you find the
35:23highest point. That extension will go up
35:24and down. Find the highest point. Then
35:26look up in here and you should see that
35:27triangle or some type of mark right
35:29there.
35:30See right here from the
35:32uh the manual. See the A where the A is
35:34pointing at little triangle on the
35:36flywheel and then the B for the mark you
35:37line it up to.
35:39That's it.
35:42Okay, going to start with the cam the
35:44intake camshaft here because the timing
35:46chain
35:48tensioner is on the backside. So, I
35:50start with the cam chain that's furthest
35:53from the tensioner.
35:55There's three dots. You have one right
35:56here and two right there. It's this dot
35:59right here that we're going to match up
36:00to the
36:01mating surface of the cylinder head
36:03here.
36:15I believe I have it. You see the two
36:16dots there? So, what I'll do is I'll try
36:18gently rolling the cam cuz this chain is
36:20just all slack down here. I want to make
36:22sure it's tight right here on this side
36:24down to the crank and then I'll know I
36:25have it right. So,
36:28that's it. The dots lined up. Okay. And
36:30exhaust. And you can always tell the
36:31exhaust cam cuz the exhaust cam is the
36:33one with the count I mean with the uh
36:35auto decompression built in on it.
36:37One dot here, two dots there. Them two
36:40dots go up there. That one dot will go
36:42right there.
36:45So, let me go up top and drop that in.
36:52Get in place up there and now I can put
36:54the chain on it.
37:09Come on now.
37:12It's tight when you have a new chain.
37:15Old worn-out chain, no problem.
37:17Tight new chain, problem.
37:27I actually got it perfect. No, no I
37:29didn't. Yeah, I did.
37:31Yes, I did. Got it perfect the first
37:33time.
37:34Sweet. What I'm doing is I have one hand
37:35back there holding the camshafts down
37:37and putting back further so you can see.
37:39Holding camshafts down
37:41in their seat and then I'm going to
37:43stick this finger right here where the
37:45tensioner would go and I'm acting like
37:46the tensioner. I'm putting tension on
37:47it. When I do that, you can see that
37:50this dot right here is lined up with the
37:53mating surface with these two up here.
37:55That dot right there is lined up with
37:56them mating surfaces with them two right
37:58there. Watch again.
38:00See that? We are timed in. So, we can go
38:03ahead and put on the cam caps now and
38:04then the timing chain tensioner.
38:07Okay, before I put assembly lube on it,
38:08get it all greasy.
38:10I'm going to Remember on the when I was
38:12doing the cam timing, I would line that
38:14groove on the bearing here to the mark
38:16that's on the head. I'm just lining that
38:18up again. That's going to help us when
38:20it's time to put the cam caps on.
38:22We don't uh they should just fall right
38:25on once we have the keyways in there.
38:26There we go.
38:29Grab some of the assembly lube. I'm not
38:31going to go crazy with this stuff.
38:33You don't have to. I just need to get it
38:35nice and wet
38:36for initial startup. Since this is a new
38:38cylinder head with new camshafts, the
38:40surfaces aren't really worn into each
38:42other yet. So, on initial startup, I
38:44just need some lube on it. Put some on
38:46the lobes, too.
38:48And um
38:51within 3 seconds, it's going to be
38:52flooded with motor oil. Don't worry
38:54about that.
38:56There we go.
38:59I'm sure you can see on the camera where
39:01I put it. A little bit on each lobe and
39:02a little bit right in the center where
39:04the bearing rides and that's all you
39:05have to do.
39:09Remember these? Time to put these back
39:11on.
39:17Don't drop them.
39:19Don't drop them in the timing chain
39:21area. They're not fun to try to fish
39:22out.
39:24If you can't fish it out with a magnet,
39:26then you got to remove the stator cover
39:28to get them out of the bottom.
39:30Okay, got them in place.
39:37New cam caps here.
39:40I'm not going to worry about putting
39:41assembly the on them cuz I already have
39:42it on the camshafts. And again, I don't
39:44want to go crazy with it. I don't need a
39:45bunch of that stuff contaminating oil. I
39:47just need it there for the first two or
39:49three seconds. And that is it.
39:55Cuz after that, it will be flooded with
39:57motor oil
39:58and it'll be washing that stuff right on
40:00out of there.
40:08There we go.
40:15All right, I'm going to take all the
40:16bolts to them. I'm going to put a dab of
40:19thread locker on each of them. Be right
40:21back.
40:22Okay.
40:42All right.
41:04There we go.
41:10Then I'll tighten them by hand. Again,
41:12there are torque specs to these if
41:14you're not comfortable tightening it by
41:15hand,
41:16um just follow the torque specs in the
41:18manual. If you do try to tighten them by
41:20hand, be careful. They are relatively
41:22easy to strip out. Just sink them down
41:24and snug them up pretty good. That's all
41:26you got to do.
41:29Okay, I'm going to make one more round.
41:31Just make sure I got them where I want
41:32them.
41:48There we go.
41:53Okay, we need to compress the timing
41:55chain tensioner before we put it back
41:56in. All right, so you stick a small
41:58flathead in here
42:00and you turn the flathead or I'm just
42:02turning the whole tensioner. You'll see
42:03you'll see that little piece, the
42:05plunger, right there
42:06uh retract inward.
42:09If I can get it in here. Here we go.
42:12Now, there's two ways to do this. You
42:13can either use that little tool, the
42:15little key, that comes with it when
42:16they're brand new, but most people don't
42:18have them.
42:19Or you can lock it in at the very end.
42:21Watch this.
42:23Get it to the very all the way tight and
42:25then you give it a little
42:27like that and it'll stay down. And then
42:30when you're done,
42:32after you get it in there, then you
42:34stick your flathead back in there
42:37and you'll hear There it goes. And then
42:39watch.
42:40That's how you do it. But we have that
42:42little tool, so we'll be using that.
42:46A little tool will come with a brand new
42:47timing chain tensioner when you buy it
42:49from a lot of brands. Um if you I don't
42:52know where to buy these at specifically,
42:54but I know that you can make them
42:56yourself just with some tin snips and a
42:58little bit of tin.
42:59Anyway, let me go ahead and um this is
43:01the brand new one right here. Um if you
43:04want to get one of these cheap and you
43:05don't want to pay the 60 or 80 bucks for
43:07OEM timing chain tensioner, but you want
43:10that tool, you can go on eBay, look for
43:12the timing chain tensioner for your
43:14bike, the aftermarket ones, the generic
43:16ones, and find one that shows the tools
43:18sitting in the tensioner.
43:21Put it in here. And just buy it for the
43:23tool, right? I wouldn't use the cheap
43:25Chinese tensioner myself, but I'd buy it
43:27for the tool. You'll get it You can get
43:30it for, you know, 15 bucks or whatever.
43:36There we go.
43:38She's locked in.
43:41It says up right there. So, be sure that
43:45you have the up facing up. And I have a
43:48brand new gasket on it, by the way.
43:56Great.
43:57Dropped one.
44:02And that that was not acorns on the
44:04ceiling.
44:12That back one could be a little tough.
44:15Once I get it threaded in by hand, then
44:18I'll just grab a extension with a
44:19swivel.
44:23There we go.
44:24All right. I got the one closest to me
44:26tightened up. Now I'm getting the one
44:27further back. There we go. Let's use you
44:31use the swivel. Now, if I can get it out
44:33of there. There we go. All right, let me
44:35tighten this one up a little bit more.
44:38All right.
44:41Let's unload the tensioner.
44:44Let me get you up here where you can
44:46see.
44:48See how the timing chain is droopy?
44:51I'm going to just going to
44:52Let me move back so you can see what I'm
44:54doing. See how it's droopy? All right,
44:55let's pull this out. This should just
44:56tighten it right up. There it is. It's
44:59not droopy anymore.
45:02Sweet.
45:06Okay, we're just going to No, there's no
45:07spark plug in it, so it's all clean and
45:10clear.
45:11Let's give this motor two rotations
45:14tations at the crank and that will
45:15rotate the camshafts one full rotation.
45:18We're checking for two things here.
45:20We're going to see if it holds cam
45:21timing. We're also going to make sure
45:23nothing binds. Like a valve doesn't hit
45:26the piston or anything like that.
45:27There's no spark plug in it, so there's
45:29no compression. I will feel you know, I
45:31will feel as if some tension as it's
45:33opening and closing the valves. That's
45:35typical.
45:36Okay, it looks like we got it. I went a
45:38little bit too far. Let me reverse it a
45:39little bit.
45:46We're looking good.
45:49Let me show you.
45:51The little triangle there is at that
45:53mark. And then up here,
45:57one of the dots is at the mating surface
45:59there. Two dots up here.
46:02One dot is at the mating surface right
46:05There it is. You can see it.
46:06And the two dots up there. We're good.
46:11Go ahead and cap this off now. If you
46:13don't put this in there, it will leak
46:14oil out of there.
46:22All right. Now, let me go ahead and put
46:24these two caps back on. Okay, I'm going
46:27to do some of the stuff off camera to
46:29speed things up, but I will hit the
46:31critical parts for you.
46:33Make sure you put that back on there
46:34before you put the valve cover back on.
46:38All right, or you'll get a nice little
46:39oil leak. And uh I'll get that in a
46:42second. And I'm going to put the new
46:43spark plug in.
46:45Okay, I went ahead and put the valve
46:46cover back on and the little vent hose
46:49that connects to the valve cover. Now
46:50it's time to get the throttle body back
46:53on. Yeah.
46:56I also, off camera, I cleaned
46:59all these uh
47:00where the sensors plug into it.
47:10We got something wrong here. Let's see.
47:44Okay.
47:45I made a mistake. It happens to the best
47:47of us, right?
47:49I put that intake manifold on the head
47:51here upside down. I have to loosen it
47:54up, turn it around, put it back on. Of
47:56course, I'm going to re-center it out
47:58like I mentioned, you know,
48:00uh just blueprinting, but I'm going to
48:01do that real quick off camera. And then
48:03we'll be able to get that throttle body
48:04on there.
48:06Okay, back at it. Woo.
48:11I was wondering why that throttle body
48:12wasn't going on, right?
48:18I was like, what the heck?
48:25That fell off.
48:31All right, let me spin it, make sure it
48:32lines up down here.
48:34There we go.
48:38Definitely want to make sure you push it
48:40all the way on there. There's a tab on
48:41the on the bottom side. Make sure it's
48:43centered out on the rubber boot.
48:52All right, now I'll tighten up the clamp
48:54forward on that side.
49:12There we go.
49:13Okay.
49:15Start plugging in some stuff here. I'll
49:17start with the sensors.
49:20This one goes right here.
49:27Okay, I'll feel injector one right here.
49:31Throttle position sensor is over here.
49:36They go in much easier now that they're
49:38all cleaned up.
49:41There we go.
49:48I've got the boot back over it. All
49:50right.
49:57Pull this off.
50:00Grab the fuel line here.
50:14There we go.
50:16All right.
50:18Keep these nice and straight.
50:24Everything's looking good.
50:26Go ahead and get this stuff connected
50:28right here.
50:35Okay, pop that in.
50:48Plug in the sensor, the
50:51engine coolant temperature sensor.
50:54There we go.
50:58And then I'm going to reconnect the
50:59ground strap right here.
51:03Put a dab of thread lock on this. Don't
51:05need a ground coming loose mid ride.
51:10Hey, let me go ahead and put the header
51:11on. I have the the exhaust gasket
51:14sitting right in the seat there.
51:39All right, pop nuts on.
51:41Finger tight. I'm going to put the
51:43second part of the header on, bolt that
51:45to that mount, and get that all lined
51:47up, and then I'll tighten all that up.
52:01This is going to be tough.
52:05Did I mention that already? I think I
52:06did.
52:28It's catching everything.
52:32Oh, I think I see what happened here.
52:37Let me fix that.
52:39There we go. The clamp on the other side
52:41swiveled and was hitting
52:43hitting the engine the head over there.
53:12Here we go.
53:22Okay, now I can tighten these things up.
53:27Just using a
53:28long extension, quarter drive extension
53:30with a swivel to reach back from behind
53:33and get it.
53:34Oh.
53:38Like that.
53:41Okay, I'm going to put these engine
53:42mounts in, one on this side, one on the
53:43other side with a dab of thread locker.
53:46Okay, went ahead and put the muffler on.
53:48Going to put some motor oil in it now
53:50before I forget
53:52cuz I'm getting antsy to start this
53:54thing up. Shell Rotella 1540. How dare
53:57you put diesel oil in it? I'll put
53:59diesel oil in it.
54:01This is good stuff.
54:03There's no reason to pay high dollar for
54:05the high-end motorcycle oils or even
54:07your standard Yamaha Yamalube 10W-40.
54:12That stuff's meant to be used in street
54:13bikes as well as dirt bikes, and because
54:15of that, it goes under a different uh
54:17EPA regulations,
54:19which um demands them to remove zinc cuz
54:22zinc is not good for the catalytic
54:23converters on your street bike. The only
54:25way to get a oil with a good package of
54:29uh
54:30engine protection properties is to
54:32either get a very high-end racing oil,
54:34and it If it's a high-end racing oil
54:36like I'm talking about, it will say on
54:38the bottle for competition use only, not
54:41for street use. That type of motor oil,
54:43because then it can fly under the radar
54:45of EPA. Or you can get just get diesel
54:47oil.
54:48Diesel oil has all the same stuff that
54:50your high-end racing oils have, and blah
54:52blah blah. So,
54:53all right.
54:55I think that's good. I see it popping up
54:57on the window. We're going to check it
54:58again after first first initial start
55:00up.
55:01Okay, pop this sucker on. Remember we
55:03have that sensor we have to plug in
55:05right here. If you don't do that, you
55:07will get a nice little check engine
55:08light, and it's easier to plug it in
55:12before you push it down on the throttle
55:14body.
55:17There we go. Let me tighten up that
55:18clamp down there from the intake boot to
55:20the throttle body.
55:22I'll go ahead and tighten up this. A fun
55:23fact for you. Did you know Do you know
55:26where the tip over sensor is on this
55:28bike? They have tip tip over sensors,
55:30right? You lay the bike down on its
55:32side, like let's say you crash on the
55:34corner and you leave the bike running.
55:36After 10 seconds, it will shut itself
55:37off to save itself because when the
55:39motor's on the side, the oil can the oil
55:41pump can starve of oil.
55:44Well, the tip over sensor on these are
55:45is actually built into the CDI. So, if
55:47you try to test testing your bike out
55:49and you have the CDI off to the side
55:51upside down, it only runs for for 10
55:53seconds and shuts off, that's probably
55:55why.
55:58So, we're going to we're going to put
55:59all this stuff together right here real
56:01quick, and we're going to give it a
56:02super quick test fire before we go any
56:04further.
56:05Okay, got the ignition coil bolted down
56:08there.
56:10Let's plug it in.
56:14That clips on right there.
56:22Make sure you get the spark plug cap all
56:23the way down.
56:28And put some thread locker on these.
56:31Yes, sir.
56:32I'm getting nervous. About to do the
56:34test fire.
56:35Don't care how many motors I've rebuilt,
56:37I always get nervous.
56:41Never know, you know? You're always
56:43hoping for the best, but you never know,
56:45you might have missed a wire or
56:47whatever. I'm pretty sure the motor came
56:49out good. I mean, everything's bench
56:51tested on it, but sometimes you just
56:52miss things out. Like I the throttle
56:54body, so I had it upside down.
56:57Things happen. So, I get a little
56:59nervous, but we'll we shall see.
57:02I'm not even going to worry about
57:02locking the coil down yet because we're
57:04going to pull the tank back up. We'll
57:06lock that down. I still have to um put
57:08the air filter on it and everything.
57:10But actually, let me just go ahead and
57:11do that real fast.
57:13There. That way, if it starts up, I
57:14won't have to lift this tank up again.
57:16We still have to put shrouds on it and
57:17stuff, but at least let me take this
57:20bungee cord off.
57:21At least I won't have to lift the tank
57:23up again.
57:39Okay, there's no engine coolant in it,
57:40but there is motor oil in it. Battery's
57:42connected. Good. Just going to do a
57:43super duper quick test fire and shut it
57:46down. I have the choke turned on.
57:49Let's see what happens. It'll take a
57:50minute to start cuz the fuel pump has to
57:52prime fuel down that dry fuel line.
57:55I'm going to keep my hand on the choke
57:56so I can shut that off right away.
58:05Sweet.
58:07Yeah.
58:08All right, that's awesome.
58:11Okay,
58:12let me get the radiator shrouds on, put
58:14the air filter on it, fill her up with
58:16coolant, put the seat on it, and then
58:19we're going to start it up, run it
58:21through some heat cycles.
58:23Okay, got a full coolant, got all the
58:25plastic on, all that stuff. Also have
58:27the new radiator supports on there.
58:29Let's go ahead and run it through a heat
58:30cycle.
1:00:50There is the hot side over here.
1:01:10Second for water leaks around here.
1:01:14Back here, oil leaks, coolant leaks.
1:01:17Also where the head gasket is at.
1:01:23Right here, this is the sensor sometime.
1:01:30The bottom looking good.
1:01:49Okay.
1:01:50Woo.
1:01:51See how hot we got her.
1:01:53Don't want to get her too hot on the
1:01:55first heat cycle cuz again, this one has
1:01:57not only a new crank, a new crank shaft,
1:02:00new crank bearings, but also has new
1:02:02camshafts,
1:02:04and uh
1:02:05a new head. Them camshafts are riding on
1:02:07that head. There's going to be new
1:02:10piston and cylinder and all that, you
1:02:11know. This is basically uh has about as
1:02:14much friction as a brand new bike. So,
1:02:17I'm just trying to uh
1:02:19cover all my bases here. Let me let it
1:02:22sit for a minute, cool off just a little
1:02:23bit. I'm going to check the oil, top it
1:02:25up if it needs it, and then we'll run it
1:02:27through a uh full heat cycle next run.
1:02:30By the way, I tried rolling that
1:02:31throttle. I wanted to just go
1:02:35And as soon as I touch it,
1:02:38that thing is just touchy. I know it has
1:02:40my brother's tune on it, my brother's
1:02:42map on it. I don't know if that's what
1:02:44it is, but that throttle is extremely
1:02:47touchy.
1:02:48Okay, now the heat cycle. Here we go.
1:03:53Clutch is a little clacky. Listen to it.
1:04:01John Hawk's going to do that sometimes,
1:04:03though.
1:05:27Okay.
1:05:28Got her to about 175° there. I'm going
1:05:30to let her cool down for 15 minutes or
1:05:33so. We'll do another heat cycle.
1:05:35Okie dokie. Let's do it.
1:06:21I'm going to let it warm up a little
1:06:23bit. I'll be right back.
1:07:04All right.
1:07:06Well, that's a wrap. Thank you for
1:07:08sitting through all these videos and
1:07:10watching the 2022 YZ250F full motor
1:07:14rebuild. She seems to be doing good.
1:07:16There's a little more clutch chatter
1:07:18than I like to hear, but you saw that
1:07:20everything's good inside the motor.
1:07:21These Yamahas typically do have some
1:07:24clutch chatter, and I suspect
1:07:26if we put some brand new plates in it,
1:07:28that'll quiet up a little bit because as
1:07:30as the plates kind of
1:07:32get used, they uh the the ends of them
1:07:34where they contact the basket kind of
1:07:35start getting mashed down, and it makes
1:07:37a little more lash over time, and that's
1:07:39what causes it. You can always tell when
1:07:41you have clutch chatter and it's not
1:07:42something else wrong with the motor cuz
1:07:43when you pull in the clutch, it'll get
1:07:44quieter, and that's just clutch chatter.
1:07:46It typically doesn't hurt anything. But
1:07:49uh otherwise, she's running great. She's
1:07:51not leaking any oil, not leaking any
1:07:53coolant. Um everything's looking good.
1:07:55Went through all five of the gears. The
1:07:56clutch is feeling good. So, we did three
1:07:59good heat cycles on it, and everything
1:08:01checked out well.
1:08:03So, yeah, he'll be breaking it in this
1:08:04weekend and seeing how she does.
1:08:07Um I appreciate all you guys sitting
1:08:08through this, and uh stay tuned for the
1:08:10next video.
1:08:12Going to be the KTM uh 450SXF
1:08:16transmission issue, missing fifth gear.
1:08:18And I also have, let me show you,
1:08:212023 YZ125.
1:08:24See the chain? See how it's strapped up
1:08:27like that?
1:08:29It uh transmission issue. It got
1:08:31stuck in gear or locked up the back
1:08:33wheel. I'm not really sure which one. He
1:08:36said it was in fourth gear, and um I
1:08:39I didn't really get the full story from
1:08:40him. I don't know if it's stuck in
1:08:41fourth gear and it won't shift,
1:08:43or if it just locked up the rear wheel
1:08:46and the chain had to be removed to push
1:08:47the bike. Not sure yet, but I'll figure
1:08:49it out, dig in, make a video on that,
1:08:51too.
1:08:52So, that's a wrap. Appreciate you guys
1:08:54that watch this. Appreciate all you guys
1:08:55out there. I'm not sure where I'll be
1:08:57riding at this weekend, um but wherever
1:09:00you guys are riding, I hope you have a
1:09:01awesome weekend of riding. Thanks for
1:09:03watching, and catch you next video.

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