Possibly swapping out forks from an '03 CR250 to '01 EC 300.

[GGRider01]

Every time I read about swapping forks all kinds of road blocks are brought up. I don't have a lot of resources available to me so I am hesitant to undertake this project. However, what I'm seeing so far makes it look like a very plausible and direct swap. My motivation is really only based on the fact that someone took the time or spent the money to set the suspension up on the 250, and it's lightyears ahead of my Gasser. So, here's what I've looked at so far.

The outer diameters are within .5 to 1mm of eachother on each bike, measured at the top and the bottom triple.

The Nissin caliper is very nearly a perfect fit on the GasGas (I tried swapping it today). I could have made it work easily by taking some meat off of the face of the top bolt hole, but decided against leaving my CR250 brakeless.

What are some things to look for before tearing both bikes apart?

Some of my concerns are, will I have to keep the CR250 front wheel? Special made spacers to keep the gasser front wheel? Rotor offset? I'm hoping someone that has experience in swapping front ends can alleviate some of my concerns and tell me what to look at before I break everything down.

 

[pj7]

Look here: http://www.gasgasrider.org/forum/showthread.php?t=11375&highlight=showa+swap

The short version if you don't want to read 17 pages is this:

On an 01 with 43mm WP forks you'll need to machine the bottom clamp larger (about 1.5mm if i remember correctly). Holes in stock top triple clamp are too large for the Showa fork so you need to have thin shims made. The CR forks are a little longer so when you install them they need to be slid up in the clamps more than your stock forks are. If you're going to use the whole front end with wheel and brake setup from the CR then that's it. Pretty easy.

If you want to use the GasGas front wheel you need to have a custom left side wheel spacer made. Luckily you would still use your GasGas axle and right side spacer since you have an 01 which has a 20mm axle. Front disc on the GasGas is larger than the Honda. Braking makes a caliper relocation bracket part #POW78 that works perfect.

 

[funmachines]

I just finished retrofitting some Ohlins forks from a Cannondale enduro onto my 06 EC300. I used the Cannondale triple clamp, axle, spacers and brake bracket. Pretty easy and the steering stops worked fine.

I did a similar swap on my sons EC200 a few years ago. I used a RMZ450 bearing and seal kit for a 2005 and it all worked fine.

Early CRF450 (2002 -2007) Honda triple clamps are the same as Cannondale too. If you want exactly the same offset as stock gasgas (22 mm) you could get 2008 crf450r, 2008 or 2009 crf250F or 2008-2012 crf450X triple clamps.

Good luck with the swap.

 

[GGRider01]

Thank you for the information, it's sometimes hard to come by. It should help a ton. We'll see how bored I get as winter rolls around and I'll probably get something going then. I definitely have a soft spot for Showa, and will probably look at swapping the rear shock too, if possible.

Cannondales are bicycles, right?

 

[funmachines]

Cannondale made dirt bikes for a little while then went chapter 11 and now only sells bicycles. They had Ohlins forks and shocks with EFI and unfortunately a lot of problems.

 

[GGRider01]

Just curious, does anyone have data on the stock Ohlins shock? I am curious what length it is. I think the CR250's shock is 488mm long. I can only find data on Ohlins' website on newer GasGas bikes and I think they use a shorter shock than the early 2000 bikes.

 

[funmachines]

Can you measure yours? I think I have an extra in the garage I could measure if you can't get to yours.

 

[coopernicus]

I've used a 1996 KX 250 shock on a 2000 EC300 with great success but I needed to use optional linkage dog bones to match the ride height. I believe my 1999 KX shock was a closer match. Since the older GGs pretty much used KX frame and suspension design, it's not surprising the KX shock is a relatively easy fit. Good luck!

Eric

 

[GGRider01]

Thanks for the info. If what I'm reading is right, the 99 KX 250 has a KYB shock. The '99 shock shouldn't need any ride height adjustment? Thanks again.

If it's not a hassle a measurement would be great, funmachines. I could measure mine but I'd only feel it would be accurate if it were off the bike and I'm not quite to the point where I want the bike out of service.

 

[funmachines]

Sorry - I did not check this thread until tonight. I'll measure one of the extra Ohlins I have and let you know.

 

[funmachines]

I got right around 458 mm.