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]

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.