My KYB SSS fork conversion / 2000 EC250

[nknudsen]

Here's my progress and info on the project as of now. I'm going a different route than some and using the the GG wheel, rotor and brake from my 2000 EC250 (super nice shape!) with conventional forks. Thank you GMP, gasgasman, Edventura and others for info. Keep in mind this is a slow process with a 6 month & 2 1/2 year old boys

2008 YZ250F forks & triples (ebay) sprung and revalved already for woods use.

2000 GG wheel remove bearing reducing sleeves and make new inner bearing spacer or buy new one from 01-03 bike. This way the 20mm Yamaha axle is fitted to the stock GG bearings.The 00' bike uses same hub as 01-03 GG.

Axle and spacers are 08 YZF stock 20mm. The wheel fits like it was meant to go there and is a bit off centered like my friends 07' YZF and 11' KX. I might make some new spacers to center it perfectly. It needs to go about .070? away from the brake side.

Brake is stock 00' Nissin dual pattern mount. Lower mount hole bolts up but upper mount hole will need to be welded shut and re drilled & tapped slightly over. I will machine spacers to move the caliper away from the fork some to match up with the GG rotor. Keep in mind the 07 and newer yz250f and 08 and newer yz450f use a smaller Nissin caliper that mounts different than the earlier yz, yzf bikes.

Steering stem bearings are a All Balls kit. I needed all the bearings, races and seals for a YZ250F. It's a very common kit # 22-1001 for the Yamaha MX bikes. Fits perfect.

Steering stop will be a machined steel piece welded to the neck in the Yamaha location.

Note: Do your research, Yamaha changes distance between lower fork legs. (axle length and spacers) and axle dia. through out the years. Later yzf have a bigger axle around 11'?

I'll post some pictures of the project in the future. I'm also doing the 2011 transformation to rid the bike of the red/pink plastic.

Noah

 

[GMP]

Good info. FYI, the newer GG front wheel hubs have the same bearing spacing, only the total width is different. All this means is that the seals ride in a different position on the spacers. I have older DID "U" wheels I use in the rocks and its been fine for years now.

 

[Danj56]

Rode yesterday for the first time since I put the KYB forks on the bike. I had Drew Smith shorten annd revalve them, the suspension worked great. The bike tracked straight through the rocks with no deflection at all. Before I changed over (I had someone else do the stock forks) the bike scared me. Going through rocks I didn't know what it was going to do. Well worth the conversion.

 

[Synergy-Seals]

Rode yesterday for the first time since I put the KYB forks on the bike. I had Drew Smith shorten annd revalve them, the suspension worked great. The bike tracked straight through the rocks with no deflection at all. Before I changed over (I had someone else do the stock forks) the bike scared me. Going through rocks I didn't know what it was going to do. Well worth the conversion.

Its amazing what good forks and suspension mods will do. My NOST KYB forks are amazing as well.

Great job!

 

[nknudsen]

Here's my progress and info on the project as of now. I'm going a different route than some and using the the GG wheel, rotor and brake from my 2000 EC250 (super nice shape!) with conventional forks. Thank you GMP, gasgasman, Edventura and others for info. Keep in mind this is a slow process with a 6 month & 2 1/2 year old boys

2008 YZ250F forks & triples (ebay) sprung and revalved already for woods use.

2000 GG wheel remove bearing reducing sleeves and make new inner bearing spacer or buy new one from 01-03 bike. This way the 20mm Yamaha axle is fitted to the stock GG bearings.The 00' bike uses same hub as 01-03 GG.

Axle and spacers are 08 YZF stock 20mm. The wheel fits like it was meant to go there and is a bit off centered like my friends 07' YZF and 11' KX. I might make some new spacers to center it perfectly. It needs to go about .070? away from the brake side.

Brake is stock 00' Nissin dual pattern mount. Lower mount hole bolts up but upper mount hole will need to be welded shut and re drilled & tapped slightly over. I will machine spacers to move the caliper away from the fork some to match up with the GG rotor. Keep in mind the 07 and newer yz250f and 08 and newer yz450f use a smaller Nissin caliper that mounts different than the earlier yz, yzf bikes.

Steering stem bearings are a All Balls kit. I needed all the bearings, races and seals for a YZ250F. It's a very common kit # 22-1001 for the Yamaha MX bikes. Fits perfect.

Steering stop will be a machined steel piece welded to the neck in the Yamaha location.

Note: Do your research, Yamaha changes distance between lower fork legs. (axle length and spacers) and axle dia. through out the years. Later yzf have a bigger axle around 11'?

I'll post some pictures of the project in the future. I'm also doing the 2011 transformation to rid the bike of the red/pink plastic.

Noah

I finally finished the fork swap and 2011 transformation on my bike. I was able to try it out at the Golden Eagles MC club trail ride in Theilman MN yesterday. Great riding as always and only open to bikes twice a year. Every thing went great for the first ride. Many riders asked what year it was and were fully confused when I said 2000. I'll post some project pics when the wife can help me get them off the camera. I'm confuser dumb!

 

[swazi_matt]

I finally finished the fork swap and 2011 transformation on my bike. I was able to try it out at the Golden Eagles MC club trail ride in Theilman MN yesterday. Great riding as always and only open to bikes twice a year. Every thing went great for the first ride. Many riders asked what year it was and were fully confused when I said 2000. I'll post some project pics when the wife can help me get them off the camera. I'm confuser dumb!

.... and .... how do you rate the conversion??? The suspense is killing me!

 

[nknudsen]

.... and .... how do you rate the conversion??? The suspense is killing me!

The conversion is well worth doing. I wanted to keep the GG wheel, brake, fender and oe type (Yamaha) steering stop so it was more involved but I love the finished product. I enjoy fabing stuff so no big deal it just takes longer. I'm messing with the comp. clickers to make the initial movement softer. The front forks make the bike feel much more capable, stable and it tracks well thru the ruts.

 

[nknudsen]

Pics of the KYB SSS project (it did happen)

Finally, here are some pics of the project. 2008 Yamaha forks, GG wheel, brake rotor & caliper (1 mount hole welded shut/relocated) with custom axle spacers on Yamaha 20mm axle. Fabbed up steering stop tig welded. Billet allum. front fender mount.

 

[nknudsen]

A couple more pics of the swap. Welding on the steering stop and the bike back together. And one for fun... me & my son with our Ski-Doo Alpine I restored a few years back.

 

[GMP]

That's a very nice job. I like your decision to use the GG wheel and would do the same thing.


Sent from my iPad using Tapatalk HD

 

[Elvis74]

@nknudsen
very nice toys you have there.
I also kept the GasGas Wheel, Brake and Brake Disc. I also use the GG axis.
Only modification was the wheel spacer and the brake caliper adater.

 

[swazi_matt]

That's a very nice job. I like your decision to use the GG wheel and would do the same thing.


Sent from my iPad using Tapatalk HD

Is that purely from a financial point of view or are there other benefits?

 

[GMP]

Because I have four GG wheelsets in total.

 

[nknudsen]

Is that purely from a financial point of view or are there other benefits?

I did it because I prefer the look of matching wheels and discs.

 

[nknudsen]

@nknudsen
very nice toys you have there.
I also kept the GasGas Wheel, Brake and Brake Disc. I also use the GG axis.
Only modification was the wheel spacer and the brake caliper adater.

Thank you! That's cool you could use your GG axle. My conventional fork axle was very small, it had oe bearing spacers to work with the 20mm bearings.

 

[gasgasman]

Excellent job on the steering stops.

 

[byost]

Beautiful work! I am curious of the steering stop, is this how the stock Yamaha is set up with the two standing lugs on the lower triple clamp and the lug on the bottom of the steering stem?

 

[gasgasman]

Yes. Same setup on the Yamaha.

 

[Coop]

Looks great, quality job.

 

[nknudsen]

Thanks everyone! I hope I never need to test the steering stop in an extreme situation.