My Walsh YZ rebuild

[gtilley45]

Well enough of my parts came in and we have about a month long break in our season, so I decided to start my rebuild. These pics were taken with my cell phone....but I'm gonna get better pics later on. I'm HOPING to have it apart and have the parts at the powdercoater sometime this coming week. That's my goal anyway.

Getting started taking it apart
http://i224.photobucket.com/albums/dd132/gtilley45/Walsh%20YZ%20rebuild%202011/rebuild6.jpg
http://i224.photobucket.com/albums/dd132/gtilley45/Walsh%20YZ%20rebuild%202011/rebuild5.jpg
http://i224.photobucket.com/albums/dd132/gtilley45/Walsh%20YZ%20rebuild%202011/rebuild4.jpg

[gtilley45]

I was wanting to run a GYTR exhaust like I had on my YFZ, so I had to go to a local muffler shop and have them cut, move and re-weld part of the exhaust for me.....but it works! :cool:
http://i224.photobucket.com/albums/dd132/gtilley45/Walsh%20YZ%20rebuild%202011/rebuild3.jpg

Put the plastic and shocks back on just to make sure the exhaust would clear everything.
http://i224.photobucket.com/albums/dd132/gtilley45/Walsh%20YZ%20rebuild%202011/rebuild.jpg

Put the new plastic, hood, and number plates on just to get an idea of what it'll look like.
http://i224.photobucket.com/albums/dd132/gtilley45/Walsh%20YZ%20rebuild%202011/rebuild2.jpg

[dehner47]

very nice set upwith the exhaust. gives me a few ideas myself.. and if ya dont mind me asking, what color scheme you goin with on the new powder?? or you just freshening up??

[gtilley45]

Yeah, I really liked that exhaust when I had one like it on my YFZ. It ran great, sounded great and seemed to be VERY good quality. Plus I've never seen a YZ hybrid with one and I thought it'd be cool. :D

The color will be very similar. The frame, subframe and few other things will be a translucent blue. It's kind of a trans blue now, but the guy that did my YFZ stuff has some awesome colors and I really liked his trans blue, I almost went with it on my YFZ. I think it looks a little better than this color. The a arms, swing arm, stem, motor mounts, and a few other things will be silver. Nerf bars, bumper, grab bar and a lot of the smaller stuff will be black. It will have white FullBore plastic, carbon fiber hood, black DFR number plates, I've got a friend working on some graphics for me if we can figure out a few details (if not, I think I might be able to get them done somewhere else), and I'm more than likely gonna have Fox shocks front and rear on it. I think it should definately stand out at the track when I'm done. :macho

[gtilley45]

Well, I got it down to the frame today. Everything is loaded up and ready to go to the powdercoater if I can find time to get by there and drop it off.

Also, it looks like I was due for some swing arm bearings. :eek:
http://i224.photobucket.com/albums/dd132/gtilley45/Walsh%20YZ%20rebuild%202011/rebuild7.jpg

[mx Eli]

you going to get shock rebuild or anything?

[gtilley45]

Getting Fox shocks.

[motochamp250]

did you just call walsh for the swingarm bearings? or what do these bikes take for future reference? cant wait to see more pics.. def makes me want a new set of fullbores haha

[gtilley45]

Yep, I got the swing arm and linkage bearings from Walsh for that exact reason.

[mx Eli]

fox for all 3? didnt know they made a cr link rear shock... never have heard anything good about fox rears too

no effense tho love the quad!

[gtilley45]

Fox isn't selling CR link rears, but they have the specs for a Laeger CR link. There's a project in the works to start building Laeger style CRF hybrids and they are gonna come with Fox shocks....a friend of mine is one of the main people behind this project. But it seems like they keep hitting wall after wall and they keep having delays for different reasons. Anyway the point is that my friend is one of the bigger Fox dealers in the country, and he said he could get me a full set of Fox shocks. We got all the measurements needed, so he said he was pretty sure they would build them. The fronts for sure and more than likely a rear too. If not, I'll probably go with custom Axis. I'm just not a fan of PEP....I know a lot of people like them, but I like Fox and Custom Axis better than PEP.

You're probably the second or third person I've heard say that about Fox rears. I had one on my YFZ and I LOVED it. I also know about 10 people personally that have Fox rears and they all love them. I will say this....I liked my Fox rear on my YFZ better than the Custom Axis rear on my LSR CRF. I know they are different quads, but both were set up for me. I wonder how many of the people who say that about Fox rears have actually had one set up for THEM.

[mx Eli]

yeah I believe that any shock will be great when set up properly, takes alot of time to get it right. love the build though keep us updated!

[JHF219]

you should add that second exhaust mount to the subframe before you powder coat it.

Here is what me and my local welder came up with. also my exhaust is a hacked YFZ pipe :D

[JHF219]

2

[JHF219]

3

[JHF219]

4

[gtilley45]

That's some nice work there JHF219! Unfortunately, everything is already at the powdercoater. I don't have anybody that can fab stuff like that for me, and I think one tab will be enough since it's a rubber mounted silencer. There is actually a couple holes in the subframe that I considered cutting the mount off the silencer itself and moving it to line up with those holes in the subframe.....and I don't know that I still won't do that.

[mx Eli]

any update?

[gtilley45]

Originally posted by mx Eli
any update?

Nope....everything is still at the powdercoater. He said middle or end of this week. About the only update is that I ordered front shocks and talked to him about getting a Fox rear shock. As has been talked about before....getting the CR500 style clevis for the bottom shock is the trick. My buddy said he knows the guy that does most of the machining for Fox, and he was gonna talk to him and see if he could talk the guy into making a clevis. I haven't checked back with him, so I don't know if he's heard back from the guy at Fox yet or not.

[Speed37]

your gonna burn your leg 4 real!!! wow that header sticks so far out dude. But heck yeah man any aftermarket shock thats set up right, will greatly satisfy you.

[250x_kyle]

looken good grant hopefully be ordering some powder and getting stuff done myself next weekend. you going to leave the new plastics plain or have some custom graphics made

[gtilley45]

Kyle- Mary is working on some graphics for me. She's never done any graphics so she's kinda learning as she goes, but I really like what she's got so far. I would like to be able to add sponsor logos into the graphics though instead of individual stickers, so we gotta figure that out.

[gtilley45]

A few people have asked me about it, so here's an update. I got it tore down and off the the powdercoater a few days ago.

http://i224.photobucket.com/albums/dd132/gtilley45/Walsh%20YZ%20rebuild%202011/Picture180.jpg
http://i224.photobucket.com/albums/dd132/gtilley45/Walsh%20YZ%20rebuild%202011/Picture181.jpg


The powdercoater finished everything up this past wednesday, so I went and picked it all up.

http://i224.photobucket.com/albums/dd132/gtilley45/Walsh%20YZ%20rebuild%202011/Picture182.jpg

[gtilley45]

Starting to put it back together. Please excuse the dark garage and the mess in the background. I've been pretty busy lately so it looks like a bomb went off with all the mess.

http://i224.photobucket.com/albums/dd132/gtilley45/Walsh%20YZ%20rebuild%202011/Picture186.jpg
http://i224.photobucket.com/albums/dd132/gtilley45/Walsh%20YZ%20rebuild%202011/Picture188.jpg
http://i224.photobucket.com/albums/dd132/gtilley45/Walsh%20YZ%20rebuild%202011/Picture190.jpg
http://i224.photobucket.com/albums/dd132/gtilley45/Walsh%20YZ%20rebuild%202011/Picture194.jpg
http://i224.photobucket.com/albums/dd132/gtilley45/Walsh%20YZ%20rebuild%202011/Picture193.jpg
http://i224.photobucket.com/albums/dd132/gtilley45/Walsh%20YZ%20rebuild%202011/Picture192.jpg
http://i224.photobucket.com/albums/dd132/gtilley45/Walsh%20YZ%20rebuild%202011/Picture191.jpg

[gtilley45]

And I just HAD to sit the new plastic on it to see what it's gonna look like. :D

http://i224.photobucket.com/albums/dd132/gtilley45/Walsh%20YZ%20rebuild%202011/Picture195.jpg

Loosely mounted the bumper.
http://i224.photobucket.com/albums/dd132/gtilley45/Walsh%20YZ%20rebuild%202011/Picture200.jpg

Also, I called and ordered my shocks. My buddy Norris said that he could get the fronts right now, and they have been ordered. As far as the rear, he said I will be able to get one......I just need to be patient. The hold up is the clevis style bottom that the shock for a CR500 linkage uses. Fox currently doesn't make that style clevis, but it's in the works. So for now I'm gonna use the PEP rear that I already have, but a Fox rear is gonna be on there as soon as I can get one. I would have gone ahead and put the rear shock on, but I ran into some trouble with the linkage. I ordered a linkage rebuild kit from Walsh, I'm replacing all the bearings while I'm doing this. (Duh) Believe it or not, I know people that re-use bearings. Anyway, the bearings in my linkage were SHOT and getting them out has turned into a MAJOR ordeal. In fact, I don't know if we're gonna be able to get them out without trashing the linkage. We're gonna try some other ideas later on today, but it looks like I might have to buy a new linkage. :(

[motochamp250]

nice to see this bike getting fixed up.... looking good man cant wait to see her done....

[250x_kyle]

Originally posted by gtilley45
Kyle- Mary is working on some graphics for me. She's never done any graphics so she's kinda learning as she goes, but I really like what she's got so far. I would like to be able to add sponsor logos into the graphics though instead of individual stickers, so we gotta figure that out.

sweet. Marys pretty dang good at that photoshop stuff. if i ever get a new job i plan on making a trip south to do some riding.

[JM317]

Is somebody local doing the powdercoating? I need to get some stuff done myself.

[gtilley45]

Originally posted by JM317
Is somebody local doing the powdercoating? I need to get some stuff done myself.
It's Not Paint in Huntsville did the powdercoating. This is the second time I've used him and I'm really happy with the work he does.

[CADWELL]

The build is looking awesome Grant, can't wait to see it with the shocks installed !

[jigg14]

Glad to see my old exhaust is being put to good use! That Pro Armor bumper looks wicked! :eek2:

[gtilley45]

Originally posted by jigg14
Glad to see my old exhaust is being put to good use! That Pro Armor bumper looks wicked! :eek2:

I'm glad you had that exhaust and didn't need it! And yeah, I settled on that bumper because I have only seen one of them on a 250R and the lines of it match the fullbore plastic pretty well.

[SilverLake250R]

Looks great!

Unfortunately a bit close to the color scheme I have planned for my Walsh 250R, but that's ok.

[mx Eli]

seems like most walsh's have that blue frame and silver looking a arms/ swing arm

the bright side is it's a great combo:cool:

[97Rocks]

Are those aarms called "long body"? I have a set just like those but mine are +4...... mine use cannondale spindles. I would like to use 450r spindles, hubs and brakes. You using 450r stuff???

[josborn]

Careful on using 450r spindles and hubs. You need the 450r kingpins from Walsh, they're different than 400ex. You also need longer upper a-arms, that are around 3/4" longer. We looked at using the +4 uppers on my wide frame, but they are just too long. Walsh is making me custom uppers right now. I think he said he would build them 1/2 to 5/8" longer to give me wiggle room.

[gtilley45]

SilverLake250R- it'll have to be ok....I don't have the money to tear it down and re-do it. LOL

97Rocks- I think the term "long bodies" refers to the gull wing looking Walsh a arms like I had before the rebuild. I've only heard these called "flatties". I'm not using the TRX450R stuff just because of the reason josborn mentioned. I have 400EX spindles, YFZ brake calipers, and a TRX450R master cylinder. I was looking into the 450R spindles and stuff, but found out that YFZ brakes will bolt right up to the 400EX spindles with no modifications.

Thanks for the compliments. I'm hoping to have it finished up this weekend...everything except setting the camber, caster, and toe. My Fox front shocks have been shipped...so I'm waiting on those, my front chain slider, and hopefully picking up my seat this weekend. I'll keep this thread updated.

[SilverLake250R]

Originally posted by gtilley45
SilverLake250R- it'll have to be ok....I don't have the money to tear it down and re-do it. LOL


I expected you to do that!!!!

No, if anyone should have to change it's me... I have everything planned out exactly how I want it, but I need a few odds and ends before it goes together...should have it done...but... I bought a road bike...bought an ATC70...bought hipers for my other bike... the list goes on. So I think it will have to wait til winter. And mine will be a little different- a metallic silver on chrome sub-theme... by that I mean silver lower arms with chrome uppers, silver bars with a chrome stem, silver swingarm with a chrome axle... Oh, and I also have white fenders, but I went with the Naca Duct hood, so that's different.

I guess since they are so close we must have picked one of the best color schemes ever ;)

[gtilley45]

Plus...you live in Michigan and I live in Alabama. It's not very likely that we'll run into each other and be like "damn, that dude copied my bike.". LOL

[gtilley45]

Update time!

My shocks came in yesterday, but the bushings for them didn't come until today. Apparently, Fox sent the wrong bushings and Quinn Motorsports had them send me the right ones. So I got those today and put the front shocks on after work. The quad is probably 90-95% finished I'd say. All that's left is installing my graphics after they're done (are pretty close to being finished from what I'm told), getting over to Quinn's to help dial in the front shocks since here isn't a whole lot of baseline info for Fox Shox on a 250R based chassis, set up the front end, and do small stuff like trim the nerf bar nets, adjust the chain and stuff like that, and of course a good cleaning. But I did ride it for the first time since the rebuild. The GYTR pipe is REALLY quiet.....like surprisingly quiet. It almost sounds like the stock exhaust on a YFZ or something. The guy I got the pipe from said it was one of the pro style GYTR's so that might be why it's so quiet. I don't see any reason this exhaust wouldn't pass tech inspection at a national. Anyway.........a few pics I got today after spraying it off at the car wash. :D

http://i224.photobucket.com/albums/dd132/gtilley45/Walsh%20YZ%20rebuild%202011/Picture201.jpg
http://i224.photobucket.com/albums/dd132/gtilley45/Walsh%20YZ%20rebuild%202011/Picture202.jpg
http://i224.photobucket.com/albums/dd132/gtilley45/Walsh%20YZ%20rebuild%202011/Picture203.jpg
http://i224.photobucket.com/albums/dd132/gtilley45/Walsh%20YZ%20rebuild%202011/Picture204.jpg
http://i224.photobucket.com/albums/dd132/gtilley45/Walsh%20YZ%20rebuild%202011/Picture207.jpg
http://i224.photobucket.com/albums/dd132/gtilley45/Walsh%20YZ%20rebuild%202011/walshfox.jpg

My buddy Cory did a little work on my new Quad Tech seat cover for me. :cool:
http://i224.photobucket.com/albums/dd132/gtilley45/Walsh%20YZ%20rebuild%202011/Picture208.jpg

[danhung11]

Looks awesome man! Love the frame with white plastics.