1987 Yamaha YZ250 Motorcycle Restoration

Skills

Organization, Small Engine Mechanics, Hand Tools, Mechanical Maintenance, Power Tools, Vehicle Restoration

Project Overview

This restoration was undertaken during evenings and weekends during an internship with Sandia National Laboratories. I undertook this project because I wanted to learn more about internal combustion engines and power transmission. I purchased a used motorcycle from craigslist, stripped every component from the frame, salvaged what I could, and replaced what I could not. During this process, it was extremely important to stay organized as there are hundreds of components. Working from a repair manual, I rebuilt the carburetor, replaced the fuel system, repaired the cooling system, rebuilt the engine’s top-end, replaced drive components, and replaced various bushings and bearings. When I lacked tools or resources, I outsourced to local shops. Since I had never learned how to ride a motorcycle, I also count learning to ride among the rewards of this project.