Planet Minis

Nooblette · 03-19-2009, 03:39 PM

Some of you may remember my other build from a while back. Lifan 150 in my YSR. Since then I have put around 6,000 miles on the small little beast with some long trips of more than 200 miles in a day and my average gas mileage was 85 MPG!!! Inspired by Shawn Basset and another guy named penguin with the RZ350 engine I started looking for another engine.

On Monday I found the engine of my dreams. It is a twin cylinder, water cooled, 250cc, TZR250 engine with YVPS made by Yamaha. YPVS is a power valve that is controlled by the ECU and servo actuated. These engines are supposed to put out 50hp stock @ 10,000RPM. This is the same engine as the TDR250 if any of you know that bike. Although I have not started tearing into my Ysr quite yet I am currently re-building the engine. The engine came with carbs, manifolds, exhaust and ECU. Here are a few pics. There is something mechanically wrong with the engine, see if you can tell what it is in one of the pics... (its not the carb)

Feedback would be appreciated!

Side View

Front View

Measurements

This should give away the problem

elitexsenate · 03-19-2009, 09:36 PM

Sweet find/motor! It'll be nice having 6 gears.

Donald_50 · 03-19-2009, 10:38 PM

Nooblette;

Yeah, WOW...TZR 250 into a YSR ! I'm impressed...best of luck (and I know it will be a whole lot of work, and some luck...) !

Back in the late '80's, I put a RD400 (yep, a Daytona Special), into a 3-wheeler with rear suspension! I had to use a rear-sled...couldn't not keep the front wheel on the ground (sand)!

First trip out to Glamis, a couple of guys offered me WAY more than I had into it ! ! ! Sold the fully inclosed trailer and the 3-wheeler...

Donald_50

Nooblette · 03-20-2009, 10:43 AM

**update**
I removed the power valve units from each of the heads. the center piece is slightly sheared and both of them will have to be replaced. The bad part is these parts SUCK! crappy cast aluminum rotary valves that are really thin. What makes it even worse is the valve is 2 pieces in each head held still by one bolt running through and 2 steel pins. The pins wear and eventually oval making a sloppy fit, then the threads in the aluminum slowly wear away to the steel hex bolt.

Rather than buying the parts new. Discontinued by Yamaha, but available in Singapore @ $100 a piece. I went to my friend @ the machine shop to have some new ones made. Yesterday we measured them out from the one good piece and he came up with a better stronger design. Plus the pieces will be machined from a billet rather than cast. For the thread problem with the screw that hold each piece together he suggested a helicoil on the new machined part so the threads don't get eaten away. They should be in on Monday. they did not have 5mm x .8mm pitch helicoils in stock

Pictures of the before and after soon to come!

tikiROAR · 03-27-2009, 09:13 PM

I sence many MORE sleepless nights once again because of your YSR

NCNSR · 03-27-2009, 09:19 PM

Good luck keep the pics coming!

Nooblette · 03-30-2009, 04:49 PM

I just talked to my friend. (the machinist) who is making my new state-of-the-art power valve and he will be making everything in solid works before he CNCs the parts from billet. I still have not picked up the metal yet so now its on me. If he gets it designed before I go on spring break I will post it up on here. More pics to come!!!

Z50R · 03-31-2009, 11:26 PM

nice! that bike is gonna be vibrating like hell

goodluck!

tikiROAR · 04-01-2009, 12:29 AM

Well i don't think the vibration will be too bad considering the motor has 2 cylinders that counter itself unlike the single. The motor also has a vibration dampener built in i believe.

Nooblette · 04-01-2009, 08:57 AM

Quote:

Originally Posted by Z50R

nice! that bike is gonna be vibrating like hell

goodluck!

That is one of the reasons I decided on a twin. It shouldn't vibrate as much as a single because the pistons reciprocating motion counteract each other. Also each half of the crankshaft is counterbalanced and if you look close the engine already bolts to rubber grommets. I will also be doing a few frame modifications though as well to keep everything as silky smooth as possible. I hate vibration as much as any other guy.

here are pictures of the pre-installed rubber grommets in the front and back of the engine. Only 2 mounts though??

Nooblette · 10-02-2009, 05:11 PM

**UPDATE**

I know its been a while since I have been on here!
The 150cc 4 stroke is coming out and being sold
The TZR cylinders are being sent to the machine shop for rod honing to .0001" out of round. New gasket kit is in, new OEM power valves are in, Everything seems to be coming together.
I have also picked up the raptor 660 Headlights to be used with the r1 body kit from ysr50.com. I want to run the curved tail piece but will have to run a plate and lights as well.

Has anyone found a way to mount the raptor lights so that they are adjustable into the ysr50 r1 street upper?

I am also looking at these Wheels:

Things should start picking up their pace now that my riding season is coming to an end! Check back often for more updates and pictures.

cdoublejj · 10-03-2009, 06:10 AM

OMG this is gonna be an epic build i can't wait for the pictures!!! Also you should power wash it or douse it in degreaser and take some pics

Quote:

Originally Posted by Z50R

nice! that bike is gonna be vibrating like hell

goodluck!

Like a Harley. I have a 155 in my z50 and it vibrates at idle not as bad when revved, I think the the big bore power vibs are cool

Nooblette · 10-25-2009, 02:32 AM

I was looking at my Build Page Realizing that it is quite bare so I thought I would share some of the parts I have been stocking up on.

Some new Pistons
These are 1MM Oversize and the engine can safely go to 2.5mm overbore.

Raptor 660 Headlights for the YSR50 upper.

<br>

My Heads have been ported, I have not polished the exhaust yet.

(still plenty of time)

Koso Digital Speedometer W/ Electronic/analog 15,000RPM Tach.
Some of you may remember this being for sale a while ago. This thing is Awesome. For those of you who done know it records water temps as well as 2 other points of your choice. Works with fuel gauges has pit speed alert and shift lights.... Too much to list!

Old Power Valve:
The original one looked like this when I took it out of the engine...

New Power Valve.
I got 2 of these OEM Yamaha parts from Australia. Seems that Yamaha doesn't sell TZR parts in the states. Surprisingly shipping was reasonable for all new parts.

Lots more parts not listed. Here are some of them. Not all of them are clean yet but Getting there slowly.

I am sending the Cylinders off to the Machine shop on the 1st of the month to get Rod Honed. I have been slacking on that.
When I start assembly I will bust out the DSLR Camera so you can actually see in my barley lit room

Let me know what you think of the parts and the build.

RepsolNSR · 10-25-2009, 11:29 AM

nooblett, nice side view, and i am not talking about the engine. ohhhhh.

Nooblette · 11-16-2009, 02:45 PM

A small update. I have cleaned up the old mounts and leftover welds from my last swap. I am cutting out frame gussets from 1/16" steel and with the help of some engineering friends strategically placing them in high stress points such as around the swing arm and headstock.

Also the new front forks have come in and I am in the process of mating the new triple tree to my headstock. New front forks are CR85 forks with a 45mm Top Clamp Diameter. These things are nice and strong! More updates and pictures to come, there just isn't much to see right now.

03-19-2009, 03:39 PM	#1 (permalink)
Nooblette 1st Gear Member Join Date: Apr 2008 Location: Fresno, Ca. Posts: 200	TZR250 w/ YPVS YSR build Some of you may remember my other build from a while back. Lifan 150 in my YSR. Since then I have put around 6,000 miles on the small little beast with some long trips of more than 200 miles in a day and my average gas mileage was 85 MPG!!! Inspired by Shawn Basset and another guy named penguin with the RZ350 engine I started looking for another engine. On Monday I found the engine of my dreams. It is a twin cylinder, water cooled, 250cc, TZR250 engine with YVPS made by Yamaha. YPVS is a power valve that is controlled by the ECU and servo actuated. These engines are supposed to put out 50hp stock @ 10,000RPM. This is the same engine as the TDR250 if any of you know that bike. Although I have not started tearing into my Ysr quite yet I am currently re-building the engine. The engine came with carbs, manifolds, exhaust and ECU. Here are a few pics. There is something mechanically wrong with the engine, see if you can tell what it is in one of the pics... (its not the carb) Feedback would be appreciated! Side View Front View Measurements This should give away the problem Last edited by Nooblette; 10-25-2009 at 02:33 AM.

03-19-2009, 09:36 PM	#2 (permalink)
elitexsenate 1st Gear Member Join Date: Mar 2008 Location: Santa Rosa, CA Posts: 103	Re: TZR250 w/ YVPS YSR build Sweet find/motor! It'll be nice having 6 gears.

03-19-2009, 10:38 PM	#3 (permalink)
Donald_50 PM Newbie Join Date: Feb 2008 Location: San Marcos, CA Posts: 16 My Mood:	Re: TZR250 w/ YVPS YSR build Nooblette; Yeah, WOW...TZR 250 into a YSR ! I'm impressed...best of luck (and I know it will be a whole lot of work, and some luck...) ! Back in the late '80's, I put a RD400 (yep, a Daytona Special), into a 3-wheeler with rear suspension! I had to use a rear-sled...couldn't not keep the front wheel on the ground (sand)! First trip out to Glamis, a couple of guys offered me WAY more than I had into it ! ! ! Sold the fully inclosed trailer and the 3-wheeler... Donald_50

03-20-2009, 10:43 AM	#4 (permalink)
Nooblette 1st Gear Member Join Date: Apr 2008 Location: Fresno, Ca. Posts: 200	Re: TZR250 w/ YVPS YSR build update I removed the power valve units from each of the heads. the center piece is slightly sheared and both of them will have to be replaced. The bad part is these parts SUCK! crappy cast aluminum rotary valves that are really thin. What makes it even worse is the valve is 2 pieces in each head held still by one bolt running through and 2 steel pins. The pins wear and eventually oval making a sloppy fit, then the threads in the aluminum slowly wear away to the steel hex bolt. Rather than buying the parts new. Discontinued by Yamaha, but available in Singapore @ $100 a piece. I went to my friend @ the machine shop to have some new ones made. Yesterday we measured them out from the one good piece and he came up with a better stronger design. Plus the pieces will be machined from a billet rather than cast. For the thread problem with the screw that hold each piece together he suggested a helicoil on the new machined part so the threads don't get eaten away. They should be in on Monday. they did not have 5mm x .8mm pitch helicoils in stock Pictures of the before and after soon to come! Last edited by Nooblette; 03-20-2009 at 10:45 AM. Reason: misspelling

03-27-2009, 09:13 PM	#5 (permalink)
tikiROAR PM Newbie Join Date: Sep 2008 Posts: 4	Re: TZR250 w/ YVPS YSR build I sence many MORE sleepless nights once again because of your YSR

03-27-2009, 09:19 PM	#6 (permalink)
NCNSR Mod formerly known as Culdesac Join Date: May 2008 Location: Garden City, N.Y. Posts: 949 My Mood:	Re: TZR250 w/ YVPS YSR build Good luck keep the pics coming!

03-30-2009, 04:49 PM	#7 (permalink)
Nooblette 1st Gear Member Join Date: Apr 2008 Location: Fresno, Ca. Posts: 200	Re: TZR250 w/ YVPS YSR build I just talked to my friend. (the machinist) who is making my new state-of-the-art power valve and he will be making everything in solid works before he CNCs the parts from billet. I still have not picked up the metal yet so now its on me. If he gets it designed before I go on spring break I will post it up on here. More pics to come!!!

03-31-2009, 11:26 PM	#8 (permalink)
Z50R PM Newbie Join Date: Jun 2008 Location: Philippines Posts: 89 My Mood:	Re: TZR250 w/ YVPS YSR build nice! that bike is gonna be vibrating like hell goodluck!

04-01-2009, 12:29 AM	#9 (permalink)
tikiROAR PM Newbie Join Date: Sep 2008 Posts: 4	Re: TZR250 w/ YVPS YSR build Well i don't think the vibration will be too bad considering the motor has 2 cylinders that counter itself unlike the single. The motor also has a vibration dampener built in i believe.

10-02-2009, 05:11 PM	#11 (permalink)
Nooblette 1st Gear Member Join Date: Apr 2008 Location: Fresno, Ca. Posts: 200	Re: TZR250 w/ YVPS YSR build UPDATE I know its been a while since I have been on here! The 150cc 4 stroke is coming out and being sold The TZR cylinders are being sent to the machine shop for rod honing to .0001" out of round. New gasket kit is in, new OEM power valves are in, Everything seems to be coming together. I have also picked up the raptor 660 Headlights to be used with the r1 body kit from ysr50.com. I want to run the curved tail piece but will have to run a plate and lights as well. Has anyone found a way to mount the raptor lights so that they are adjustable into the ysr50 r1 street upper? I am also looking at these Wheels: Things should start picking up their pace now that my riding season is coming to an end! Check back often for more updates and pictures.

10-25-2009, 02:32 AM	#13 (permalink)
Nooblette 1st Gear Member Join Date: Apr 2008 Location: Fresno, Ca. Posts: 200	Re: TZR250 w/ YPVS YSR build I was looking at my Build Page Realizing that it is quite bare so I thought I would share some of the parts I have been stocking up on. Some new Pistons These are 1MM Oversize and the engine can safely go to 2.5mm overbore. Raptor 660 Headlights for the YSR50 upper. <br> My Heads have been ported, I have not polished the exhaust yet. (still plenty of time) Koso Digital Speedometer W/ Electronic/analog 15,000RPM Tach. Some of you may remember this being for sale a while ago. This thing is Awesome. For those of you who done know it records water temps as well as 2 other points of your choice. Works with fuel gauges has pit speed alert and shift lights.... Too much to list! Old Power Valve: The original one looked like this when I took it out of the engine... New Power Valve. I got 2 of these OEM Yamaha parts from Australia. Seems that Yamaha doesn't sell TZR parts in the states. Surprisingly shipping was reasonable for all new parts. Lots more parts not listed. Here are some of them. Not all of them are clean yet but Getting there slowly. I am sending the Cylinders off to the Machine shop on the 1st of the month to get Rod Honed. I have been slacking on that. When I start assembly I will bust out the DSLR Camera so you can actually see in my barley lit room Let me know what you think of the parts and the build.

10-25-2009, 11:29 AM	#14 (permalink)
RepsolNSR "Thou shalt not touch others bikes" Join Date: Nov 2008 Posts: 247 My Mood:	Re: TZR250 w/ YVPS YSR build nooblett, nice side view, and i am not talking about the engine. ohhhhh.

11-16-2009, 02:45 PM	#15 (permalink)
Nooblette 1st Gear Member Join Date: Apr 2008 Location: Fresno, Ca. Posts: 200	TZR250 w/ YVPS YSR build A small update. I have cleaned up the old mounts and leftover welds from my last swap. I am cutting out frame gussets from 1/16" steel and with the help of some engineering friends strategically placing them in high stress points such as around the swing arm and headstock. Also the new front forks have come in and I am in the process of mating the new triple tree to my headstock. New front forks are CR85 forks with a 45mm Top Clamp Diameter. These things are nice and strong! More updates and pictures to come, there just isn't much to see right now.

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