My 48mm Kayaba Project

[Ed Ventura]

I have my 2011 300 with 45mm zokes working pretty well. It is time for me to rebuild my 2007. Problem is I dont have a set of forks for it. I have looked around a little for a set of 45mm zokes with out much luck. After reading the many threads on fork swaps I decided to try a set of Kayaba's from a 2007 YZ250F. I could not find a thread on in's and out's of this so I will document it hear.

I have a set of Ebay forks on the way. They can be had very resonable. I gave $275 for a set with the tripple clamps. They were descrided as great shape, we will see.

I have a set of 2006 GG clamps that I will have bored. The 2006 clamps I have are 6mm thick. They do not have 2 spots machned down thinner like some of the newer clamps. I will use the yamaha clamps diameter asa guide for the machine shop.

It will take a few weeks for this to all come together.

Pics and more to come over the course of this swap

 

[wheelie]

Sounds like a fun project

 

[Ed Ventura]

Here is a poor quality pic of the GG lower clamp I will be using. As stated above it is 6mm thick. It;s overall inside diameter will need to be bored around 2mm. leaving the thickness around 5mm.

After I get the Forks on the frame I will look at wheel and brake options, GG wheels would be best I have 3 fronts already. But a yamaha setup will probablly be much easier to do. Tons of used yamaha wheels for sale.

Ed

 

[GMP]

Ed,

I can verify Brent's findings that the newer GG clamps for the 48mm Sachs and Zokes are just bored out 45mm clamps. I guess GG is not worried, and the fast team guys are not breaking them, so should be good.

I'm going to eventually do the same thing to my '07. Picking up a 200 motor and another set of wheels in a couple weeks so I'd be interested in a custom caliper bracket/axel/spacers to use them.

 

[skid jackson]

ed i believe there is a netra racer that has an alternative front end for an 11 300 for sale. Woodsknight over on nedb. might be something that works on your 07. he's done a few project bikes so he knows the ins and outs of those sort of things

 

[whodat]

hope this helps

I put complete front end from 2007 yz250f on 2005 300 ec. clamps, forks, wheel, brake.Every thing fit perfect seems yami and gasgas have identical head stock tube.

 

[GMP]

Does it steer the same? What are the clamp/axel/total offsets? Good info.

 

[whodat]

I think there was a slight diff in trail. maybe 1 or 2 mm. handling was not the same as the KYB SSS was a huge improvment. steering seemed just as good as before.

 

[Jakobi]

Didn't the 2010/2011 models with the B frame use a smaller head stem so it wouldn't work on those bikes?

 

[GMP]

OD of neck smaller, stem I believe is the same.

 

[Jakobi]

So the triples would drop in.. Good info!@

 

[rpduc]

Any chance the OP could measure (or does anyone happen to know) the OD of the tubes at upper/lower clamp positions?
I'm thinking of replacing the 50mm Zokes on my MC 250 with KYB SSS forks. I'm thinking I might be able to use my triples with shim stock or if I was really lucky...

 

[Ed Ventura]

Any chance the OP could measure (or does anyone happen to know) the OD of the tubes at upper/lower clamp positions?
I'm thinking of replacing the 50mm Zokes on my MC 250 with KYB SSS forks. I'm thinking I might be able to use my triples with shim stock or if I was really lucky...

As soon as the forks are in my hands I will measure them.

I am curious about the axle offset compared to my zokes.

I bought them on ebay for 275 with tripple clamps. The seller then said they were in need of fork seals so he sent them for new seals and bushings which delayed them a few days. Sounds to good to be true but I have a tracking number and expect them later this week

ED

 

[GMP]

Guys, do a search, this has been done awhile ago and all these measurement numbers exist.

 

[rpduc]

Yeah Glenn I found your post with "the numbers" in that epic thread by Brent M. on his Showa conversion... But I see you had the same question as I do. Do the Husky and Yamaha KYB SSS measure the same? I would assume that KYB didn't make a different fork for Husky, but I'll be damned if I can confirm measurements from a Yamaha anywhere. I was gonna head for the Yamaha dealer but if Ed's gonna have a set in his hands soon I will wait.

Thanks Ed. That stinkin E-bay can be a little scary but sounds like you got a screamin deal. And the guy's having the things rebuilt to boot. Crazy!

 

[GMP]

Ross,

I'm talking about a thread farther back that had the all the data. Hope its not lost.

 

[rpduc]

Well any thread other than the Brent M. Epic that contains this:

http://www.gasgasrider.org/forum/showpost.php?p=77397&postcount=19

is lost on me. But I never have figured out how to search forums in any specific way.

I was poking around at Cafe Husky to see if I could find any info on my Zoke 50 mm closed chamber forks. If I read correctly it appears that at least some of the Huskys are running an open chamber 48 mm KYB. Maybe the same tubes with different internals? Cripes all of this is making my head spin. Snippets of info everywhere but no comprehensive listing anywhere that I can find.

 

[Vindicator]

I was poking around at Cafe Husky to see if I could find any info on my Zoke 50 mm closed chamber forks. If I read correctly it appears that at least some of the Huskys are running an open chamber 48 mm KYB. Maybe the same tubes with different internals? Cripes all of this is making my head spin. Snippets of info everywhere but no comprehensive listing anywhere that I can find.

Nope, everything is KYB. CC for the MX model, OC for the Enduro models.
You have a detailed service manual for your 50mm Marzocchi at the website :

http://www.marzocchi.com/template/listManuals.asp?t=&tp=128&idMY=56695&Azione=Search&IDFolder=180&LN=UK&idC=1686

Just choose the year of your forks.

 

[rpduc]

Thanks for the link Vin... they only list 2009 and 2010 tech manuals and I already have a the Marzocchi tech manual for my 2005 50mms.

I did find a thread on Cafe Husky from '09 with bleeding procedure for the 50mm Zoke CC forks which I will definitely try.

 

[GMP]

I'm talking about something older. It had all the different fork tube and clamp dimmensions. There is a chance I have the info somewhere, I'll check tonight.