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Author Topic: 2006 to a 2002 YZ250. Need some help  (Read 4189 times)

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Offline Smithdad

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2006 to a 2002 YZ250. Need some help
« on: July 02, 2013, 11:57:35 PM »
Ok guys I need some assistance. I have a 2006 YZ250. Lost crank bearings in it so I pulled the motor. It is just sitting there waiting for parts to come back from the shop etc. I also have a 2002 YZ250 with a good motor just sitting there. It has a split in the gas tank that makes it very uncomfortable to ride. So I pulled the motor out of it and with a few minor mods at the swing arm I put it in the 2006. I am using the carb from the 06. Pretty much everything but the motor itself is 06. After getting it all together it fires on the first kick. Now for the problem. It is running wide open. The throttle is closed and it won't idle down. We turned it off with the kill switch. Made some adjustments and tried again. Same result but this time the kill switch won't work. Finally got it stopped. Pulled everything back down and I can't find anything. All of the electronics and the carb are 06. No changes there. Any ideas. Thanks.
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline ford832

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2006 to a 2002 YZ250. Need some help
« Reply #1 on: July 03, 2013, 12:27:30 AM »
There may be something with how the 06 CDI works with the 02 ignition-assuming that's your setup but failing that.I'd look inside your carb to make sure the slide is all the way down-not just that the twist grip is "closed".It sounds like the cable ferrule is hung up on the top of the carb under the rubber boot.
On the other hand,if you couldn't stop it with the kill switch it sounds like a no load runaway-in other words,an air leak.If this is the case,you can't kill it with the switch but putting it in gear and releasing the clutch(putting it under load) will stop it instantly.
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline Smithdad

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2006 to a 2002 YZ250. Need some help
« Reply #2 on: July 03, 2013, 01:00:24 AM »
The slide is all the way down. I have checked the routing of the cables to be sure nothing is kinked.
THe throttle is working fine but I will pull the top of the carb off and check it thoroughly. I will also check for an air leak. Thanks
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline _X_

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2006 to a 2002 YZ250. Need some help
« Reply #3 on: July 03, 2013, 01:49:09 AM »
try changing the black box from 02 to 06.
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline Smithdad

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2006 to a 2002 YZ250. Need some help
« Reply #4 on: July 03, 2013, 02:16:18 AM »
Good idea. I know the plugs are the same.
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline Smithdad

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2006 to a 2002 YZ250. Need some help
« Reply #5 on: July 03, 2013, 01:59:07 PM »
CDI boxes are not interchangeable. Wiring is completely different. Can't find a an air leak and the cable seems fine. Not sure what to do next?
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Offline _X_

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2006 to a 2002 YZ250. Need some help
« Reply #6 on: July 03, 2013, 02:32:26 PM »
did you try converting the wire harness as well as the box? this would make them compatable.
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline Sheriff

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2006 to a 2002 YZ250. Need some help
« Reply #7 on: July 03, 2013, 09:33:46 PM »
If it has been sitting for a long time, it's possible that some rubber dried up somewhere causing an air leak. If you're gonna swap the CDI, you're gonna have to swap the harness and coil at least.

Stupid question though, why didn't you just swap gas tanks and ride the 02?
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Offline Smithdad

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2006 to a 2002 YZ250. Need some help
« Reply #8 on: July 03, 2013, 10:38:25 PM »
Mainly the suspension. IT just sounded like a good idea so my son could ride. Quick engine swap. Get a few hours on the bike and swap back to the new motor when it comes in. Wasn't planning on all of this but now it has turned into a have to project just to make a point to myself.
I am going to swap all the wiring in the morning to see what happens. New motor will probably come in about the time I get it all going and I will have to swap it all back. 
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Offline _X_

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2006 to a 2002 YZ250. Need some help
« Reply #9 on: July 03, 2013, 11:25:19 PM »
ha! thats usually the case smithdad.
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline ford832

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2006 to a 2002 YZ250. Need some help
« Reply #10 on: July 04, 2013, 12:15:37 AM »
In order to run wide open it needs air-lots of it.It's hard to imagine not a carb issue or air leak.Just out of curiosity,why did you swap the 02 engine and electrics,but go with the 06 carb?
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline Smithdad

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2006 to a 2002 YZ250. Need some help
« Reply #11 on: July 04, 2013, 10:50:55 AM »
Quote from: ford832 on July 04, 2013, 07:15:37 AM
In order to run wide open it needs air-lots of it.It's hard to imagine not a carb issue or air leak.Just out of curiosity,why did you swap the 02 engine and electrics,but go with the 06 carb?

That is a great question. I don't have a good answer. I wasn't planning on having to swap the electronics from the start.
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Offline Smithdad

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2006 to a 2002 YZ250. Need some help
« Reply #12 on: July 05, 2013, 11:50:54 AM »
Ok kind of embarrassed that I did not catch this. Turns out the cable was frayed at the top of the carb. One strand was turned back up inside the housing. It was only sticking intermediately because both times I checked the carb the slide was closed. Pulled the subframe again yesterday and it was stuck open about 1/4 inch. Took the carb off to check it all out and found it. New cable fixed it all. Feel bad I did not find that quicker but glad it turned out simple. Now I don't have to swap all that back over with the new motor.

New question. The YZ250 air intake brings alot of air into the bottom of the airbox. We ride a lot of sand here and what seems to be happening is an accumulation of sand at the very bottom of the filter. Now I change my filters after every ride so it is not "dirty" but at this point. When I changed the filter yesterday I noticed some grains of sand inside the rubber boot between the filter and the carb. I use DT1 filters with the neoprene boot and have had no problems in the past. I believe what is happening is that some dirt falls in the boot when I remove the "dirty" filter. Not sure how to stop that. I was considering closing up the hole in the bottom some and adding air vents to the box. Maybe putting in some foam at the bottom of the airbox. Any experience with this?
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline ford832

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2006 to a 2002 YZ250. Need some help
« Reply #13 on: July 05, 2013, 12:18:59 PM »
Hey,you found it-good stuff 8)
You can brush your filter off a bit before removing it or put a filter skin over it-or one of the old woman's nylons.
You could trying greasing the seal of the filter to improve sealing but I don't-though some do.
Is your drain open at the bottom?My 02 has a baffle designed such that nothing could really get up there.
If sand is getting in it will settle to the bottom-naturally- then "bounce" up and stick on the bottom of the filter when going over bumps/jumps.
Regardless,with the speed of a dirt bike,they don't much care where they get their air from.If you wanted to block off the bottom and vent it elsewhere it wouldn't matter.
My KTM's used to  put a lot of dirt to the airbox.When riding in a lot of dusty conditions I'd take a layer of old filter or other  light foam and stick it dry over the airbox vents.It helped a lot with minimal air restriction.

« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline Smithdad

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2006 to a 2002 YZ250. Need some help
« Reply #14 on: July 05, 2013, 01:13:01 PM »
Used to grease the snot out of the filter base. THe DT1 has a neoprene base and they say do not grease it. Been using them for a while now and really like them. Had not had a problem in the past. I checked the filter base and the air box surface and there was not an area that looked like there could be a pass thru. It had to come from the bottom of the filter when it came out. I am going to try the foam I use for heavy mud in the vent at the bottom of the air box and see how that works.

Thanks for all the help.
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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