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The ATVriders.com Yamaha Raptor 250 Build
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Posted by: Pappy

When Yamaha released the Raptor 250, many felt it would fit along side its sub 300cc counterparts and just be another starter atv for young adults and beginner riders. Once the machine actually hit the showroom, that opinion changed rapidly as it broke away from other 250cc models and set it's sights on being at the top of the class.

Sport oriented, race inspired design, custom colors/graphics and shown in may an advertising photograph ripping berms and shredding dirt. That's dandy from a marketing stand point, however in the real world being top dog requires proving yourself in farm fields and race tracks all across the globe. Whether the new Raptor 250 would live up to the hype was yet to be seen.

After visiting our local dealership and inspecting the new machine in 2007, we felt the Raptor would allow us a platform to begin a build on this machine that could pull duty on the XC and MX world for our 14 year old rider. Being that our rider is short in stature, the lightweight (313 LBS dry) and overall smaller size would be just the machine to allow him to compete with.

Posted by: Pappy

Keeping the machine basically stock for the first few months would not be hard as very few aftermarket companies had yet to embrace the new machine. Yamaha's GYTR team had just about everything covered however from bumpers to exhaust if one wanted to immediatley start adding on the goodies they had to offer. We chose to sit back and watch as slowly companies started making more and more products for the atv. It wasn't long before suspension, exhaust systems, graphics kits, control arms/swing arms were on the market allowing one to really start building on what Yamaha had given us in stock form. Still we chose to ride the machine stock and see what issues we felt would need to be attended to as we started planning our eventual build. The machine itself has alot to offer and stock for stock would get my vote for best 300cc or below atv model in it's class. The stock suspension is adequate for it's target market, it handles decent for being a fairly narrow platform and the power is more then enough to keep it right beside any other model in this range. For a price tag just under $3700 it could well be the perfect starting platform for a young rider that is ready to step up to a manual clutch and more power. If your rider is above 5'8", I still feel the Honda 300ex may be a better fit, but this is subjective and up to what the rider feels comfortable with. With all the typical model info long since released, we got the ioppertunity to really dig into this machine and see if what it offered out weighed any drawbacks we would find.

Posted by: Pappy

Riding and learning took up the better part of late summer and early fall as the Raptor just kept chugging along. We also had a Honda 300EX here that was set up with the typical modifications to offer us a side by side comparison. Our rider was able to put laps in on both machines and literally had his pick of which machine to either keep or sell. When it was all said and done, for our rider the Raptor suited him best and the 300ex was sold to help fund the build up of the new machine.

Due to a few injuries, we were unable to race the Raptor until round #12 of the GNCC series. A kill switch and Maxxis tires were added for the race to help stave off flat tires and give us a bit more ground clearence. After almost 3 months of not racing, our rider was soon off the line as we put the machine to the ultimate test.

Posted by: Pappy

With our rider admittedly not being at 100%, he was still able to work his way from the last row to mid pack out of almost 380 riders. His feedback from this race allowed us to zero in on a few areas that he felt needed attention, the biggest being suspension. The Raptor is nimble, and can dart in between tree's or avoid large rocks, but at race speeds and under real world conditions, the stock suspension was being riden way over what it was designed for. Other then that, power again was reported to be great and no other issues were found during the two hour race.

Posted by: Pappy

As fall turned to winter, planning was at full speed as products were ordered in for the build. GYTR got the nod for almost every component they offered. Knowing that we should not have fitment issues with GYTR products, we decided on running one more local race to get one last feel for where we were headed with our planning for the build up. I reckon this was a good thing, because I was almost ready to cancel my order to Lonestar Racing for wider arms and axle as we felt we could be fairly competitive aboard the stock parts and only have to splurge for shocks. This local race really brought out the short-comings of the stock suspension as it was brutally rough and incredibly wet providing us with another area of testing to see how waterproof the machine was. The two hour race only reaffirmed our thoughts on upgrading the entire suspension and the rest of the atv never missed a beat. We did have the stock chain stretch and gave our rider fits as each lap it would force him to get the chain back on and run until it derailed once again. Other then a loose change, the Raptor had given us flawless performance for well over 5 months.

Posted by: Pappy

I know of no other torture test an atv could be put through then to be the daily ride of a 14 year old not to mention the addition of adding the abuse of racing. The Raptor may not be perfect, but it was holding it's own as it took everything we were throwing at it. With the year coming to an end, the New Years Eve race would be the final task of the machine in stock trim as the follwoing week tear down would begin.

Posted by: Pappy

With the machine a bare skeleton, I turned my attention first to the frame. 5 months of racing and riding had shown no cracks to the frame, however from expierence I saw a few areas that I felt needed beefing up, first of which was near the steering stem. 11 gussets in all were welded in to strengthen the chassis for the racing that lay ahead. The frame, swing arm and steering stem were then powder coated white to help our machine stand out.

Posted by: Pappy

Now here is where I will draw fire from the manufacture as I think they went a bit to cheap on the chassis. That lightweight and lightest in it's class numbers have to come from somewhere and a light frame is certainly one way of accomplishing those numbers. The frame in size is in between a TRX90 and a Blaster. I do like the round tube construction, but durability in my opinion will be a major concern with the motocross riders out there. Hey, I also know that we push these machines a heck of alot further then what Yamaha designed it for and we all know this models is not being touted as a Race machine but face it, this model will be out in force at tracks all over this country, so without bashing the manufacture, you will need to pay attention to the chassis if you intend to race this machine.

Posted by: Pappy

Assembly began on the race machine while we started adding some protection to our practice quad. Just like most stock machines, the protection included is minimal at best. For general riding the factory installed plastic skid plates are fine, but for more aggresive trails, more is needed.

Posted by: Pappy

With the factory chassis skidplate removed, you can see just how vunerable the engine is.

Posted by: Pappy

A GYTR chassis skid plate was added to offer us more protection and as you can see, it has fended off many a rock as this skidplate was previously installed on our machine. The fit was perfect and installation a snap. Access holes to all drain bolts line up and are easily reached.

Posted by: Pappy

The swing arm protection would be again provided by GYTR and everything fit like a glove. The GYTR products may be a tad bit higher priced then other aftermarket products, but having parts that fit correctly is a huge plus in my book. For GNCC racing, I feel the skidplate would need to be of thicker design but again, this item is designed for the average rider in average terrain.

Posted by: Pappy

Nerf bars for the Raptor are few and far between at the time of this writting. GYTR was again johnny on the spot and again, perfect fit and finish as they mounted easily. Black or Blue nets are available

Posted by: Pappy

Pro peg nerfs are soon to be on the market for those that need more then a standard nerf, however for most the GYTR nerf is all that is needed.

Posted by: Pappy

For added protection up front, a GYTR MX bumper was aquired to replace the small factory unit. These come either bare aluminum or powdercoated black.

Posted by: Pappy

Upgrading the factory air filter is something that most atv owners do and while I was ordering the GYTR products, I went ahead and got their billet adapter and filter that strengthens the air filter moint and increasea air flow to the engine. Installing the billet adapter was not hard but it will take some time to get everything apart and reinstalled.

Posted by: Pappy

The added airflow of the GYTR intake systems would help as the GYTR performance headpipe and silencer was installed.

Posted by: Pappy

The GYTR exhaust is among one of the best for not only the Raptor, but also for other models Yamaha offers. It was lighter then the stock exhaust which should take some of the stress off the subframe part of the chassis, and power output is reported to be good throughout the power curve. Later this spring we will be visiting a dyno for some more reports and we can actually see then what kind of power the little thumper is putting out.

Posted by: Pappy

One issue we have with almost every model of atv and our rider is that his lack of height causes him to be unable to lift the rear of the quad out of a mudhole. PRM was called and one of their new grab bars for the Raptor was ordered. The PRM unit follows the stock subframe angle but then levels off, allowing our rider to be able to lift the machine where the stock grab bar continues to follow the chassis and is to high for it to be of any use for us.

This is also where we ran into our first fitment issue as the grab bar dcontacts the end cap. This will be addressed and material will be removed from the grab bar to allow the proper clearence.

Posted by: Pappy

The GYTR bumper with a natural finish will be called to duty on the race quad.

Posted by: Pappy

The first step into the unknown on this build was the front brakes. Stock, the Raptor comes equipped with single piston calipers and we feel that stopping power is equally important as increaded power and speed. The addition of YFZ450 dual piston calipers were added for braking that will stop on a dime and hand you back change! The swap was a direct bolt on, all that was required was YFZ450 calipers and mounting brackets, the remainder of the front spindle assembly and rotor were retained from the Raptor.

Posted by: Pappy

Turning our attention to what we had found racing the machine, Lonestar Racing was called for a set of their new +3 +1 Long Travel control arms. These arms boast castor and camber adjustability and are constructed of chromoly. Installation was straight forward although I would prefer a slip style upper ball joint mount for easier camber adjustments. The arms came complete with everything needed to install them including directions and a lifetime warranty, something we may just need racing the GNCC Series.

The extra width will help stabilize the raptor at high speeds and allow for better cornering. With a 4-1 rim, we will be at 47 inches width.

Posted by: Pappy

Elka suspension has backed almost every build we have ever done, and while we do not get the shocks for free, we do get the best customer service and support from them wether it be a call from our shop or tracksde at a race. Their Long Travel shock for the LSR arms are a piece of work, offering is high and low speed adjustability which should help us dial in the new set up. Being that many of us will for the first time be taking the Raptor to the Nationals, more adjustment is a huge benefit as we learn what works best.

Posted by: Pappy

Elka was also responsible for the rear shock that offers full adjustability. The no link design used on the Raptor was fairly decent in stock form, but now will really shine as rough terrain is tackled at speed.

Posted by: Pappy

The stock swing arm was retained, and another borrowed part from the Raptors big brother, a LSR Sprocket gaurd for a YFZ450 bolted directly on and should offer us protection and ground clearence, both of which are in high demand on such a small machine.

Posted by: Pappy

An adjustable Lonestar chrome axle rounded out the rear end and offers us adjustablility and added strength over the stock unit.

Posted by: Pappy

Pro Taper cr double hi handlebars will be utilized along with their new grips. A MSR adjustable clutch perch and lever replaces the factory unit and a Pro Design kill switch keeps us legal for GNCC competition.

Posted by: Pappy

And to round out the list of parts, a set of Steamline stainless brake lines replaced the factory lines for even more imporved braking up front. A set of Lonestar racing brake line clamps keeps everything secure.

Posted by: Pappy

Future plans are to add a Lonestar Antivibe Steering stem and a bar mount style steering damper for increased rider control. These items are being built and were unable to be included in this article. The machine will now under go normal break in runs to assure we have everything race ready and to check things like jetting. GYTR jetting was used during this build and from our first test ride seems to be pretty close for our elevation. Look for more articles as we put the new products to the test in the Can AM GNCC Series!

Posted by: Mxjunkie

That thing is trick!

Posted by: TWISTED DINLI

quote:
Originally posted by Mxjunkie
That thing is trick!

X2!!
is the GYTR exhaust the best one for it right now?

Posted by: Pappy

quote:
Originally posted by TWISTED DINLI
X2!!
is the GYTR exhaust the best one for it right now?

"Best" is hard to define really. It fits well, is well made, and provides a decent upgrade in power. The problem with defining "Best" is that setting a "What is best and why" has so many variables and personal likeness to some form of test is hard. Shear dyno numbers would help, but who wants a pipe that makes good power and comes apart every 3 races

or one that makes power and is so loud you piss off everyone inside a 3 mile radius

I was actually very surprised at how quiet this set up is, I usually stay away from aftermarket due to noise, but this one seems to be just right.

Posted by: Pappy

We now have 2 GNCC races on the machine in built form. One area we all need to keep an eye on is the left rear lower engine mount! Ours cracked as did others!

Other then that, the quad did well!

Posted by: Pappy

With just an exhaust, it had plenty of power to get to the front of the pack at the hoelshot

Posted by: Pappy

Everything other then the engine mount held up fine on one brutal track

Posted by: Pappy

Round 2 found us preparing for one muddy event. ITP tires were installed, 21x7x10 front GNCC's and 20x10x9 GNCC rears. The sizes of the ITP tires fit very well with the small machine and the added traction would be huge in this race

Posted by: Pappy

The start at round 2 wasnt as good for us due to Cody having a shifting issue, but he ran right up into the thick of things

Posted by: Pappy

The new tires were hooking up great and he was doing well after a bad start

Posted by: Pappy

He managed to get through the entire race without getting stuck until the last lap when he clipped a tree and it sent him into a bootomless pit where he had to wait to be winched out

Posted by: Pappy

We made it home and washed her up, and last night he put in an hours practice. He loved the new tires and said he had so much confidence in them that he was taking lines he knows he would have been stuck in before.

We will keep everyone updated as we roll into round 3

http://farm3.static.flickr.com/2389/2326929953_8f83d7dd6d_o.jpg

http://farm4.static.flickr.com/3021/2326970265_feaeb80407_o.jpg

Posted by: Pappy

many more hours of riding has proven to us that this is a decent machine, however the frames are goiing to come apart quickly.

http://farm4.static.flickr.com/3016/2334432800_28c323dd35_o.jpg

http://farm3.static.flickr.com/2253/2333562513_8bb3b66bf2_o.jpg

http://farm4.static.flickr.com/3093/2332245434_95da643c15_o.jpg

http://farm3.static.flickr.com/2182/2332231304_4a2333ae23_o.jpg

http://farm4.static.flickr.com/3165/2332194236_288b914352_o.jpg

Posted by: Pappy

A few new action shots

http://farm3.static.flickr.com/2049/2356380342_f8a8b6d590_o.jpg

http://farm4.static.flickr.com/3138/2356163722_37d87f13ab_o.jpg

http://farm3.static.flickr.com/2362/2355274937_4c1b6f2de6_o.jpg

Posted by: wanta450

what exactly do you mean by frames are gonna come apart quickly ??

Posted by: Pappy

They are going to be prone to cracking and breakage when pushed hard. This is just something to be aware of, as this model was not designed to do what we know will be done with them (not many are)

As of right now, we have only had to deal with one crack, and that was near the left lower engine mount, but we havent turned it loose on a mx track

Posted by: TheNewn

What a lucky kid, hope he knows that!

Looks like a great starter racing quad, i'd like to see some dyno's on it. Curious how this motor compares to the 300EX motor.

Posted by: Pappy

16 hp or so stock, low 20's with a cam.

I saw several more units this weekend with the lower left engine mount cracked....looks like we have a problem Yamaha should know about.

Here is a shot from friday at the GNCC in North Carolina before the race

<a href="http://www.flickr.com/photos/8622360@N03/2372843557/" title="FLA_8573a by mycamerahatesme, on Flickr"><img src="http://farm4.static.flickr.com/3292/2372843557_6766d68c46_o.jpg" width="1000" height="669" alt="FLA_8573a" /></a>

Heading in for the last lap in this shot. The quad performed well, but he is now giving me a list of things he wants in an updated release from Yamaha

Posted by: jakes

Pappy, checked my son's Raptor 250SE, and his friend's - both were cracked at the left bottom engine mount as well.

Posted by: Pappy

Hoefully the dealers will stand behind the mount breaking.

Here a few action shots during practice for the upcoming GNCC

<a href="http://www.flickr.com/photos/8622360@N03/2397393080/" title="itp 042a by mycamerahatesme, on Flickr"><img src="http://farm4.static.flickr.com/3123/2397393080_e1a6d76bd0_o.jpg" width="891" height="1000" alt="itp 042a" /></a>

<a href="http://www.flickr.com/photos/8622360@N03/2396553369/" title="itp 029a by mycamerahatesme, on Flickr"><img src="http://farm3.static.flickr.com/2326/2396553369_e6e005e09e_o.jpg" width="1000" height="721" alt="itp 029a" /></a>

<a href="http://www.flickr.com/photos/8622360@N03/2397373664/" title="ITP Shoot by mycamerahatesme, on Flickr"><img src="http://farm4.static.flickr.com/3206/2397373664_62093722de_o.jpg" width="1000" height="716" alt="ITP Shoot" /></a>

Posted by: 250racer2010

why do you not run nerfs

Posted by: Grndpadirtrider

So are they cracking at the weld or some place else on the tab? What do you think is the cause of the cracking?

Posted by: Pappy

All I can figure is the frame is flexing and cracking the mounts. There were no loose bolts or any other cause we can find

Posted by: Grndpadirtrider

I will have to keep an eye on this thanks for the photo.

Posted by: reckless216

quote:
Originally posted by Pappy
All I can figure is the frame is flexing and cracking the mounts. There were no loose bolts or any other cause we can find

we think we have found cause of frame breaking its the chain when bike is under full load ( compressed chain is at its tightest and when fully exstended very loose) we have fitted a chain slide of banshee onto laeger swingarm so chain can re-main loose without coming of sprocket 9 mx meetings still no cracks !

Posted by: bradley300

quote:
Originally posted by reckless216
we think we have found cause of frame breaking its the chain when bike is under full load ( compressed chain is at its tightest and when fully exstended very loose) we have fitted a chain slide of banshee onto laeger swingarm so chain can re-main loose without coming of sprocket 9 mx meetings still no cracks !

interesting find, and very likely if the countershaft is too far away from the swingarm pivot. i raced a kymco with the same issue, we fixed it by simply adjusting the chain with the rider on. it looked extremely loose w/o a rider, but just right once the rear suspension compressed

Posted by: hr15

On our Raptor the tab on the opposite side is welded everywhere it is touching the frame,it has not cracked yet.The other looks like pappy's pic.Looks like they set it up to weld and missed the mark a little.