YZ250 Blaster Build Log

Tbrock77 · Jun 21, 2015

I'm making this thread to share my progress of my YZ250 engine swapped blaster. I'm sure I'm going to make many mistakes as I go through this build and I'm hoping by sharing my progress I will help others avoid these mistakes. If you have any suggestions or concerns as I go along feel free to comment with them but keep them constructive and clean. I will be sharing what I spent once the build is done so people can get an idea of how much it costs to do this kind of build.

So far this is what I have for the build.
- 2005 rolling chassis
- radiator on it's way
- bumper on it's way
- light bar on it's way
- Stage 3 Elka's front and rear on their way

I'm picking the bike up Tuesday 6/22, it's a 1987 YZ250. I've heard it run but it supposedly needs carb work. I'm going to compression and leakdown test it as soon as I get it to make sure it's ready for the swap. If it's not, the swap will wait until I can fix the issue.

A couple goals for this build are
- keeping parts from other makes or models to the minimum for convenience
- One piece pipe that is removable without taking everything apart and uses a Blaster silencer
- Keeping vibration to a minimum using rubber mounts

Tbrock77 · Jun 21, 2015

I swapped the newer style steering stem for an older style so I can mount a light bar to it, that way while I'm turning I will be able to see where I'm going. I plan on running a battery to power the lights since the YZ doesn't have a lighting coil.

Awk08 · Jun 21, 2015

tuned in for this, good luck.

btw, have you seen this, 18 pages of yz250 swap goodness ..............
http://www.blasterforum.com/threads/got-a-2001-yz-250-for-my-blaster.24529/

Tbrock77 · Jun 21, 2015

Awk08 said:
tuned in for this, good luck.

btw, have you seen this, 18 pages of yz250 swap goodness ..............
http://www.blasterforum.com/threads/got-a-2001-yz-250-for-my-blaster.24529/

I read through each of the YZ builds I found on this site.

YZ Otis · Jun 21, 2015

I can smell a thread like this from across the country .. Good luck, have fun & do it your way!

Blasturd · Jun 21, 2015

Subscribed!

This is gonna be a fun one to watch!

harley1-5 · Jun 21, 2015

awesome deal

bansheedave · Jun 21, 2015

kx250 swaps are the same process

Tbrock77 · Jun 22, 2015

Got my bumper in the mail today

Test fitted on the quad and then tried a radiator I had laying around to see how it fit. The radiator I ordered is for a Polaris predator 500. I think it's a bit taller than this one so I'm not 100% it will fit without modifying the bumper a bit. We will have to wait until that comes in, should be here within the next few days. The radiator will be centered behind the bumper and I will have to make custom mounts for it. I'm doing a front radiator to leave plenty of room for the pipe and for lots of cooling for the motor. The bumper should protect the radiator.

79 bronco · Jun 22, 2015

Larry's Shee · Jun 22, 2015

I see advantages and disadvantages there. Weight is lower, but far forward. Tho with the YZ should have enough powwa to lift the wheels.

Biggest drawback is rad cap will be lower than most of engine. Which will make "burping" the system impossible.
You'll need to add a tee, length of hose, and fitting with either a plug or cap so that it's the highest point of cooling system.

Tbrock77 · Jun 22, 2015

Larry's Shee said:
I see advantages and disadvantages there. Weight is lower, but far forward. Tho with the YZ should have enough powwa to lift the wheels.

Biggest drawback is rad cap will be lower than most of engine. Which will make "burping" the system impossible.
You'll need to add a tee, length of hose, and fitting with either a plug or cap so that it's the highest point of cooling system.

I'm not sure it will be drastically lower. I will fill the system then lower the radiator in place so I don't have any air bubbles. That shouldn't be too much of a hassle.
As for the weight being in the front, I don't mind. I prefer all 4 on the ground.

Larry's Shee · Jun 22, 2015

BRILLANT !!

Never thought of that. Be slight pia initially, but not bad.

bansheedave · Jun 22, 2015

No way to fit a rad in the frame the way it sits?

Tbrock77 · Jun 22, 2015

bansheedave said:
No way to fit a rad in the frame the way it sits?

I want to leave room for the pipe, there wouldn't be enough room if I tucked it up in the frame.

I picked up a second 2003 roller today for $250

now if only I could find another yz250 haha

Blasturd · Jun 22, 2015

How is it going to work out to plumb the radiator all the way back from in front of the suspension?
Just something to think about.

Tbrock77 · Jun 22, 2015

Blasturd said:
How is it going to work out to plumb the radiator all the way back from in front of the suspension?
Just something to think about.

I'm going to try to put a 45 or 90 off the radiator to put the hoses on the inside of the frame. I looked before I decided to mount it on the front and there should be plenty of room for the lines without any issues with the suspension or pipe.

Larry's Shee · Jun 23, 2015

Just a suggestion. Might look in an auto junk yard, some cars have pretty crazy preformed hoses. Even if you didn't find a good hose, you could go to A Z and get a new one.

Tbrock77 · Jun 23, 2015

Larry's Shee said:
Just a suggestion. Might look in an auto junk yard, some cars have pretty crazy preformed hoses. Even if you didn't find a good hose, you could go to A Z and get a new one.

Great idea! If it seems like running normal hose is going to cause an issue I will definitely look around.

Larry's Shee · Jun 24, 2015

Just straight rad/heater hose might kink. So with size you need probably be looking for heater hoses.

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