2005 ec250 --> 2011

Still waiting on a few odds and ends to ship, but it didn't stop me from taking her for a spin around the neighborhood.

Still need:
New silencer,
Frame protectors,
Rebuild the rear brake
 
I think the white frame is a nice touch. It really looks good with the new plastics and graphics.
The whole bike looks so clean.

I''m partial to those colors; maybe because I raced a couple of '87 WR430 Huskys for 9 years. :)

Good Riding!
Jim



--
 
KYB SSS Fork Swap

Since I already have this thread going, I wanted to continue in the evolution of my GasGas: Maybe this should be in the suspension section, but I'll keep it here for now.

I wanted to keep the GasGas wheel (2010) since I had spare wheels and the GasGas front brake caliper. The YZ Axle is 20mm, my GasGas Axle was 25mm. I used 20mm bearings from an older GasGas and made a spacer... I'll probably make a one piece spacer when I get some lathe time.

Parts Used:

$12.99 1996-2003 GasGas Front Wheel Bearing and spacer kit
$56.00 Braking 260mm Caliper - Bracket Part Number POW106
$260 2007 YZ250F Front Forks (Valved for woods already by Factory Connection) and Axle
$74 2005 YZ250F Triple Clamps (Billet upper triple made by Applied)
$27 MSR Fork Seals and Wipers
$26 All Balls Steering Stem Bearing Kit 22-1001
---- Rear 20mm wheel spacer and a 3mm shaved down 20mm spacer
 




Rebuilt the forks with new seals, wipers and bushings.


I cut out this octagon out of steel and welded a nut to it to remove the cartridge. I know I could buy a tool, but what fun would that be. On other forks, I've used a large bolt head, but this thing is octagonal, not hexagonal, like a bolt head.






Welded a small tab to the steer tube to act as a steering stop:


The spacers I put together for the caliper side of the axle:




260mm YZ Caliper bracket allowed me to use the gasgas caliper
 
LHRB and Clutch

You may notice some craziness on my left side of the handlebar.

On my KTM 300, I've done this and have gotten really used to it. I wanted to do it to the GasGas too. I've tried just about every setup. Rekluse LHRB, Clake Pro and Clake 2, and the Smokn setup on my KTM. They are all a pain in the ass to bleed and I got marginal performance out of them. The best setup I've run is converting a clutch to a brake. I can lock up the rear brake with one finger and I am able to modulate it effectively. On a steep downhill, it is like riding a mountain bike. Just lean back and not worry about foot position.

I used an old bark buster mount for 7/8" handlebars and drilled/tapped a small section of 7/8" aluminum round stock. This acts as a perch for my clutch. Since I use a Rekluse Auto Clutch, I don't have much use for the clutch, but it is nice to be able to grab the clutch occasionally and start the bike in gear or for the occasional pop of the front end or whatever.

I used a Magura 9.0mm clutch master cylinder from a KTM 125. I'm still playing around with what size master cylinder I like best. I have a Brembo 9.5mm master on my Ktm and that has really light pull with a Midwest Mountain Engineering Lever. Both setups let me lock the rear wheel up. The Magura 9.0 has a much firmer lever feel... this might lead to more hand pump. We'll see.

On my KTM, I used a SMOKN adapter to retain use of the foot brake (which I never use anymore). I thought it would be nice if ever someone else wanted to ride the bike. On the GasGas, I ran the brake line directly to the caliper and removed the foot brake assembly.



 
RockefellerGG said:
Since I already have this thread going, I wanted to continue in the evolution of my GasGas: Maybe this should be in the suspension section, but I'll keep it here for now.

I wanted to keep the GasGas wheel (2010) since I had spare wheels and the GasGas front brake caliper. The YZ Axle is 20mm, my GasGas Axle was 25mm. I used 20mm bearings from an older GasGas and made a spacer... I'll probably make a one piece spacer when I get some lathe time.

Parts Used:

$12.99 1996-2003 GasGas Front Wheel Bearing and spacer kit
$56.00 Braking 260mm Caliper - Bracket Part Number POW106
$260 2007 YZ250F Front Forks (Valved for woods already by Factory Connection) and Axle
$74 2005 YZ250F Triple Clamps (Billet upper triple made by Applied)
$27 MSR Fork Seals and Wipers
$26 All Balls Steering Stem Bearing Kit 22-1001
---- Rear 20mm wheel spacer and a 3mm shaved down 20mm spacer
Click to expand...

Excellent work.
I've seen several Gassers that have been equipped with the Yamaha forks. Yours is the first that I've seen that kept the GasGas front wheel with the swap.

What spacer did you use on the front wheel? Did it come with the front wheel bearing kit, or is that the Tusk package?
What rear wheel spacer (supplier/brand & model?) did you use?

I'm always looking for parts sources and crossovers.
Thanks in advance, and Good Riding!
 
I used a rear wheel spacer from an older gasgas that had the 20mm axle and added a 3mm shim that I created by grinding down another wheel spacer. You could use an older gasgas 20mm front wheel spacer and add a 6mm spacer.

If I recall, the distance between the forks was 131mm. I placed wheel in the forks and had the rotor clamped inside the caliper. With the seals removed, I took measurements.

On my setup the front wheel is centered between the forks.
 
Jim Cook said:
Excellent work.
I've seen several Gassers that have been equipped with the Yamaha forks. Yours is the first that I've seen that kept the GasGas front wheel with the swap.

What spacer did you use on the front wheel? Did it come with the front wheel bearing kit, or is that the Tusk package?
What rear wheel spacer (supplier/brand & model?) did you use?

I'm always looking for parts sources and crossovers.
Thanks in advance, and Good Riding!
Click to expand...

Here's another thread (mine) using the GG wheel & brake with the KYB forks.
http://www.gasgasrider.org/forum/showthread.php?t=14592
 
Yeah, I certainly didn't pioneer this swap, but I wish I had done more searching on here. It would have led to less measuring and buying useless parts. It took me a while and a few useless parts before I found the right brake caliper bracket.

Also, I like that machined steering stop. That thing is so beefy! Makes my 1/8" thick tab look so weenie.
 
RockefellerGG said:
I used a rear wheel spacer from an older gasgas that had the 20mm axle and added a 3mm shim that I created by grinding down another wheel spacer. You could use an older gasgas 20mm front wheel spacer and add a 6mm spacer.

If I recall, the distance between the forks was 131mm. I placed wheel in the forks and had the rotor clamped inside the caliper. With the seals removed, I took measurements.

On my setup the front wheel is centered between the forks.
Click to expand...

Thanks for your reply.
 
Anders said:
Nice work!


I also used the Gasgas wheel in Kyb forks. I turned suitable spacers on my lathe and kept the 25mm ID bearings. I made a 250mm brake disk (keeping the Gasgas caliper) instead of using an adapter to move the caliper outwards.

Sent fra min GT-I9295 via Tapatalk
Click to expand...

The brakes have plenty of power to lose 5 mm off the radius of the rotor.
Great thinking.

I need to go on and get that lathe I've been talking about.

Thanks for the information.
 
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