front wheel question
 

hi all, i have a question im trying to use sachs 48mm forks on a 2004 ec250 and the front wheel will not work with the 2009 axle and spacers. it is larger than the 04 is it possible to switch to the 2009 front wheel bearings to accept that axle?

Yes you will need to get new bearings seals and the spacer between the bearings

What year bearings would I need? Would the 2009s fit the 2004 wheel?

Normally, the bearings would be the same and the axle diameter catered for by the spacers.

My personal experience of Sachs forks on a 2015 Beta is that they are complete garbage. I would be looking at anything other than Sachs. If KYB would fit your year, go for those, imho.

Here is my dilemma. The bike had absolutely shot ohlins forks that had issues and needed the lower tubes coated. Also the bike came with a set of true works ohlins forks but the wheel spacers didn't work and we cut them down only to have the fork bind up and not work properly and I happened to have the sachs forks because on the 09 model switched to 50mm marzoccis so I have 3 sets of forks that are virtually worthless to me and the sachs set seemed to be the best option plus I have a brp clamp for them.

The Sachs does not have the best reputation, but some have reported decent performance from them. And with an Ohlins cartridge kit they behave very well, I have been told. But that's another story, and a lot of cash.
To me, the works Ohlins forks sound like the best bet. Is it only the spacers that is the problem? If so, a set of spacers is easily made up by anyone with a lathe and a set of calipers.

Yes, but the OEM Gasgas hub has no space for bigger bearings. So they opted for the low profile bearings when they went from 20 to 25mm axle.

I did like you suggest when I installed the Yamaha axle in the Gasgas wheel when doing my Kyb conversion on my 06 EC200.