Installing a GYT-R Pipe on a New Raptor 250

EnricoPavia

December 07 2008
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Words by Nick Nelson Photos by Enrico Pavia

THE NEW YAMAHA RAPTOR 250 is an unbelievably fun little quad. After riding one, you will undoubtedly be left with a smile. The only thing we could ask for on ours was a little extra hoursepower, but then again we think every quad can benefit from a little boost in the power department (check out our story on page 51 of issue 22 April 2008 for plenty of horsepower know-how). Lucky for us, Yamaha was quick to release a GYT-R exhaust system, jet kit, and air filter system. It woke our little Raptor up tremendously, and we will show you the step-by-step way to install it on your 250.

STEP 1

START YOUR PROJECT WITH a clean quad and workspace. This is important, as you will be removing multiple pieces for access. Remove the seat, front plastic, and the gas tank. Unhook the battery ground and remove the rear plastic. (EASY)

STEP 2

REMOVE THE STOCK exhaust pipe and place it out of the way. Remove the battery from the box, relocating all of the electrical wires to the side of your quad. You will have to lift the rubber hangers straight up individually to detach the electrical assemblies from the airbox. (EASY)

STEP 3

DISCONNECT THE CRANKCASE breather tube from the airbox. Loosen the hose clamp connecting the airbox to the carburetor and remove all of the hardware holding the airbox to the frame. Pull the rubber boot off the carb and remove the airbox. (EASY)

STEP 4

REMOVE THE HEX NUTS that secure the plastic air filter flange to the airbox and remove the stock filter setup. It will be necessary to bend the airbox intake tube to allow access to the hardware. Install the GYT-R plate with the supplied buttonhead Allen bolts and red Loctite. (EASY)

STEP 5

REMOVE THE VACUUM CHAMBER cover from the top of the carburetor. Remove the needle assembly and disassemble it and keep all the pieces in the order they are removed. We sometimes use an empty egg container for these kinds of steps so we can keep all the pieces in order and separate. Replace the stock needle with the GYT-R needle, and put the clip set at the third position from the top. (INTERMEDIATE)

STEP 6

LOOSEN THE HOSE CLAMP and tilt the carburetor to access the float bowl screws. Carefully remove the screws with the appropriate, high-quality screwdriver, as they have a tendency to strip (and that spells big headache). Remove the bowl, replace the main jet with a number 135, the pilot with a number 27.5, and set the fuel screw to two turns from the bottom. (INTERMEDIATE)

STEP 7

INSTALL A NEW GYT-R HEADPIPE, paying attention to the stock headpipe gasket, making sure it’s still in the head and undamaged. If the gasket is damaged, replace it. Install the GYT-R muffler with the supplied grommets and gasket. Twist the carburetor back to straight and tighten the clamp. (EASY)

STEP 8

REINSTALL THE AIRBOX ONTO THE FRAME and carburetor, and tighten the hose clamp. Then reinstall all the electrical assemblies. Install the fuel tank, rear plastic, and front plastic. Hook up the ground wire on the battery and replace the seat. Now you’re ready to rip it up with your new pipe! (EASY)

SIDEBAR

THE RAPTOR 250 you might think that this little quad is too tiny to be fun, but you’d be wrong! Yamaha’s new entry-level Raptor 250, with a little horsepower jump thanks to the GYT-R pipe, is one of the most fun, lightweight quads we’ve ever ridden. It has a 249cc air-cooled SOHC four-stroke engine mated to a five-speed gearbox with manuel clutch. Whether you’re a beginner or an old pro, and whether you’re a small fry or a big guy, the 250 offers plenty of power and performance for less than $4000.