GGman KYB conversion
 

My previous bike had the 50mm 'zokes on it. (now enjoyed by Jay)
I really liked the lack of flex on them. My Current 45mm 'zokes just seemed to wallow in the ruts and deep sand.
I usually stay off the ground, last couple rides I've hit the dirt like 3 times. The front end would just loose traction and down I went.

So, decided to try the KYB conversion.
Thanks to EdVentura, GMP and Danj56 for their valuable input.
It was a LOT of work and well worth it. I rode today and the stock YZ valving seemed spot on. Front tire stuck like velcro. My confidence was very high. I did not get arm pump and my arms are not sore at all.

Here's my build. I found some brand new 2012 YZ 125 KYB forks on e-bay.
Parts used;
2012 YZ KYB SSS forks and guards.
2010 YZF 250 3x clamps.
2009 YZ 250 Front wheel w/ axle and spacers.
2010 YZ450 front caliper.
Replaced GG upper steering stem bearing with same one as the bottom.
Two door stops from HomeDepot.

I wanted to use the OEM GG fender and headlight. The YZF bottom clamp has two vertical pins that aren't used. So I cut threads on the pins to mount a bracket to hold the GG fender.
http://i79.photobucket.com/albums/j1...ps93e35b8f.jpg

Bracket shown here. I drilled two new holes aft of the GG OEM rear holes.
http://i79.photobucket.com/albums/j1...ps036b3b41.jpg

For the fork stops, I installed some PopNuts in the frame to hold the door stops I bought from HomeDepot.
http://i79.photobucket.com/albums/j1...pscb17c423.jpg

Door stops mounted. I have since shortened them to regain some steering angle.
http://i79.photobucket.com/albums/j1...pscbfd0328.jpg

Fork stop in action.
http://i79.photobucket.com/albums/j1...psf0178642.jpg

Top clamp install. I used the GG top bearing seal. The GG damper mounted up perfectly.
http://i79.photobucket.com/albums/j1...ps8f4c0f0c.jpg

http://i79.photobucket.com/albums/j1...psfeb33091.jpg

Headlight mounted up. Little far out on the bottom. Not bad though.
http://i79.photobucket.com/albums/j1...ps484e2182.jpg

Side view. Front wheel did not hit the fender at all.
http://i79.photobucket.com/albums/j1...ps2fe9529f.jpg

The fork compression is set at 11 clicks and the rebound is 6 clicks.
Now I have to get the shock to match the front forks.:rolleyes:

looks like alot of work... glad it works great...

(and yes.. those 50's are sweet )

jay

What did you do about the stem? Is the YZ stem close enough that you only replaced the upper bearing? Stem length is fine? If you don't mind, can you post up your total cost on parts?

The stem is the YZF part.
The GG stem is smaller at the top and requires a smaller bearing.
The YZF stem is the same diameter for the entire length.

I'll add up the parts and let you know.
The brand new forks were $800 from e-bay. I bought new because I did not want someone's hack job.
e-bay seller has a crap load of new parts.
http://stores.ebay.com/328-Power-Spo...fsub=404612719

What spring rate? OEM ? Do you plan swapping springs?

Very sweet. Nice job.

Very nice. Thank you for sharing. I love seeing people's ingenuity.