Hybrid Warrior a.k.a Frank

Yamaha Raptor 350 & Warrior Forum

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Joined
Feb 12, 2021
Messages
24
Reaction score
11
Location
Smithville, MO
This build started out its journey just like every other build on here, a bone stock Warrior.

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That turned into a Wiseco .5mm over stock 10.25:1 flat track quad with a 37mm FCR, ported head and a Dyna programmable cdi.

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More to come very soon....
 
This motor was to the point it needed a rebuild and I wanted to take the build in a different direction. This is where I started looking for a donor motor and happened to find a 2004 YZ250F that had a fresh rebuild.
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Once I got it home and the engine pulled I checked it over and didn't like what I found. It was not a fresh build and after tearing it down there was a rock in the bottom end, so I figured if it's getting rebuilt we are building it. Made it a fresh 290 big bore, sent the carb out to Jet Labs to get taper bored from 37 mm to 40 mm and had the head ported to maximize gains.
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Picked up a Vortex CDI and YFZ450 radiator.

Now this lead to the fun part of getting this to sit in and work properly.
 

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here is the full build list, more pictures and progress updates to come.

Chassis | Suspension | Controls



Frame: Modified Warrior

A Arms: Armed +2

Swingarm: Modified Stock

Steering Stem: Alba +2 Banshee anti vibe

Stabilizer: N/A

Axle: +2/+4 relabeled G Force

Carrier: Stock

Locknut: 2 piece G Force

Hubs F|R: YFZ450 front and rear hubs

Bars: Flexx bars

Throttle/Clutch Lever: ASV YFZ levers

Grips: ODI lock on

Nerfs: Alba Raptor 350

Pegs: Modified Raptor 350

Bumper: YFZ450 Rath

Grab Bar: YFZ Houser EZ Lift

Front Shocks: YFZ450 revalved/resprung

Rear Shock: Banshee

Brake Pads: EBC red

Brake Lines: braided Calipers: Stock

Rotors F|R: Alba Chomper rotors

Rims F|R: DWT A5 | DWT blue label

Tires F|R: American Racer | Maxxis Razr TT



Body



Plastic: Modified Stock/YFZ450 radiator shrouds/Custom hood

Graphics|Seat Cover: custom Graphics | custom Moto Seat seat cover

Number Backgrounds: white

Handguards: Powermadd handguards

Bar Pad: Custom Flexx pad

Fuel Tank: Stock

Skids plates: Modified bottom of frame to include skid

Lighting: N/A



Engine|Drive System



Cylinder Head: Ported YZ250F

Gaskets: Cometic

Piston: Athena 83 mm

Cam|Valves Springs: Kibble white Titanium

Bore & Stroke: 83 mm x 53.6 mm

Displacement: 290cc

Carburetor: taper bored 37mm FCR

Spark plug: NGK Iridium

Stator: Stock

Shifter: Hammerhead

Air Filter|Box: Modified open air filter

Header|Silencer: Shortened DRD

Clutch|Plates|Springs: Tuck Heavy duty clutch and springs

Gearing F|R: 13/39

Chain: O-ring

CDI|Killswitch: Vortex x-10 | teethered kill switch

Cooling: 2 computer fans/Engine Ice

Other: rear lowering link
 
Here is where the fun began, it was time to modify the frame..
Since this is a dedicated race bike i wanted to shed as much weight as possible and also add as much strength in weak spots.
I cut out everything on the rear subframe, added gussets and added a integrated skid plate to the front.
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Added mounts for the radiator and oil tank.

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And then had to do a mock up to figure out wehre to modify the stock swing arm to fit the rear motor mount.

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After figuring out I cut too much out of the first swing arm I redid it again on another and this time it was a perfect fit.

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and boy did it look good in there.

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then i wanted an anti vibe stem, after hours of research and comparing stems i found that a banshee stem i could get to work.
After modifying it slightly it fit like a glove and gave me +1.5" anti vibe stem.

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Finally the engine was all put together and it was time to finish mock up.

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Found out the DRD exhaust can was a little too long so chopped it down to make it fit.

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A little more detailed build list, forgot a few things on the first one.

Chassis | Suspension | Controls

Frame: Modified Warrior
A Arms: Armed +2
Swingarm: Modified Stock
Steering Stem: Alba +2 Banshee anti vibe
Stabilizer: N/A
Axle: +2/+4 relabeled G Force
Carrier: Stock
Locknut: 2 piece G Force
Hubs F|R: YFZ450 front and rear hubs
Bars: Flexx bars
Throttle/Clutch Lever: ASV YFZ levers, TRX90 throttle with custom aluminum cover
Grips: ODI lock on
Nerfs: Alba Raptor 350
Pegs: Modified Raptor 350
Bumper: YFZ450 Rath
Grab Bar: YFZ Houser EZ Lift
Front Shocks: YFZ450 revalved/resprung
Rear Shock: Banshee
Brake Pads: EBC red, YFZ450 left caliper with a Hansen modified mount
Brake Lines: front braided, rear stock
Calipers: YFZ450 calipers
Rotors F|R: Alba Chomper rotors
Rims F|R: DWT A5 | DWT blue label
Tires F|R: American Racer | Maxxis Razr TT

Body

Plastic: Custom cut stock/YFZ450 radiator shrouds/Custom hood
Graphics|Seat Cover: custom Graphics | custom Moto Seat seat cover
Number Backgrounds: black
Handguards: Powermadd handguards
Bar Pad: Flexx pad with custom cover
Fuel Tank: Stock
Skids plates: Modified bottom of frame to include skid
Lighting: N/A

Engine|Drive System

Cylinder Head: Ported 2004 YZ250F
Gaskets: Cometic
Piston: Athena 83 mm 12.5:1
Cam|Valves Springs: Kibble white Titanium
Bore & Stroke: 83 mm x 53.6 mm
Displacement: 290cc
Carburetor: taper bored 37mm Jetlab FCR
Spark plug: NGK Iridium
Stator: Stock
Shifter: Hammerhead
Air Filter|Box: Modified open air filter, K&N pod filter
Header|Silencer: Shortened DRD
Clutch|Plates|Springs: Tusk Heavy duty clutch and springs
Gearing F|R: 13/39
Chain: O-ring
CDI|Killswitch: Vortex x-10 | teethered kill switch
Cooling: 2 computer fans/Engine Ice, YFZ450 radiator
Other: rear lowering link
 
Finally got a few minutes to check the valves and ended up finding a few things wrong. Exhaust valves were out of spec, got those reshimmed, front motor mount for the swap is cracked and has a ear broke off. Now to get some metal and rework this mount to keep it from cracking again.

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