04 YZ250 to SSS 09 YZ250F Fork conversion

Jamo29
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Jamo29
Edited Date/Time 1/1/2021 7:28pm
Hey guys I know this have been covered a few times but I've just bolted on a set of 2009 YZ250F SSS KYB forks to my 2004 YZ250. Everything seems fine and went together all good except the bottom of the fork lugs seem to be pulled in slightly. The 04 YZ250 axle is longer than the 09 YZ250F, so this makes me think I need the 09 YZ250F triple clamps as they must be slightly narrower. Has anyone put 09 yz250f clamps on a 04 yz250?

Also from my research on the oem parts list shows the 2004 YZ250 front wheel to be the exact same as the 2009 YZ250F, is this correct?

Any help would be grateful appreciate, Cheers Jamin.
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Jamo29
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Jamo29 12/26/2020 7:22pm
12/26/2020 7:22pm

1
Mr. Robinson 12/26/2020 8:20pm
12/26/2020 8:20pm
It should work if you used the '04 axle.
Jamo29
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Jamo29 12/26/2020 8:35pm
12/26/2020 8:35pm
When I use the 04 axle it overhangs by a mile, but yeah might have to just run it. Cheers for the response
Jamo29
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Jamo29 12/26/2020 8:37pm
12/26/2020 8:37pm

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beamer
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beamer 12/27/2020 4:27am
12/27/2020 4:27am
If it was me I would run the ‘09 triple clamps. I did a similar conversion on a rm250 and run the proper clamps for the forks (‘98 conventionals on a ‘08)
You may be lucky and maybe the steering stems will match up, but not sure.
2
Mr. Robinson 12/27/2020 6:47am
12/27/2020 6:47am
Did you use the '09 spacers with the '09 axle? I'm trying to remember what combination to use, but it can be done. If I remember right the difference is in the axle lugs, but it's been over 10 years. Maybe someone that's done it more recently will chime in.
1
Jamo29
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Jamo29 12/28/2020 1:38am
12/28/2020 1:38am Edited Date/Time 12/28/2020 2:00am
Jamo29
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Jamo29 12/28/2020 1:58am
12/28/2020 1:58am
Mr. Robinson wrote:
Did you use the '09 spacers with the '09 axle? I'm trying to remember what combination to use, but it can be done. If I remember...
Did you use the '09 spacers with the '09 axle? I'm trying to remember what combination to use, but it can be done. If I remember right the difference is in the axle lugs, but it's been over 10 years. Maybe someone that's done it more recently will chime in.
Yeah I used the 09 spacers with the 09 axle and everything seems to button up pretty good, except for how the bottom of the forks are slightly tweaked in. I'm away from home atm so haven't been able to go back and have a play but I'm thinking if the 09 yz250f clamps will pair up with the steel frame it'll work.

I originally thought the front wheels may have been different but the oem part numbers for the front wheels on both bikes are exactly the same.
Jamo29
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Jamo29 12/28/2020 1:59am
12/28/2020 1:59am
beamer wrote:
If it was me I would run the ‘09 triple clamps. I did a similar conversion on a rm250 and run the proper clamps for the...
If it was me I would run the ‘09 triple clamps. I did a similar conversion on a rm250 and run the proper clamps for the forks (‘98 conventionals on a ‘08)
You may be lucky and maybe the steering stems will match up, but not sure.
Cheers mate, I'll try find some 09 yz250f clamps and hopefully they'll work on the steel frame without too much fabricating.
Mr. Robinson 12/28/2020 6:36am
12/28/2020 6:36am
Jamo29 wrote:
Yeah I used the 09 spacers with the 09 axle and everything seems to button up pretty good, except for how the bottom of the forks...
Yeah I used the 09 spacers with the 09 axle and everything seems to button up pretty good, except for how the bottom of the forks are slightly tweaked in. I'm away from home atm so haven't been able to go back and have a play but I'm thinking if the 09 yz250f clamps will pair up with the steel frame it'll work.

I originally thought the front wheels may have been different but the oem part numbers for the front wheels on both bikes are exactly the same.
Yeah, the hub is the same for sure. I'm sure you'll get it figured out.
1
FWYT
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FWYT 12/28/2020 7:22am
12/28/2020 7:22am
beamer wrote:
If it was me I would run the ‘09 triple clamps. I did a similar conversion on a rm250 and run the proper clamps for the...
If it was me I would run the ‘09 triple clamps. I did a similar conversion on a rm250 and run the proper clamps for the forks (‘98 conventionals on a ‘08)
You may be lucky and maybe the steering stems will match up, but not sure.
Hey, I certainly don't mean to hijack this thread, but do you have any stuff posted somewhere about your fork conversion? I am planning to put those Showa conventionals on my next build as well and have some questions.
1
Jamo29
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Jamo29 12/28/2020 9:00am
12/28/2020 9:00am
Jamo29 wrote:
Yeah I used the 09 spacers with the 09 axle and everything seems to button up pretty good, except for how the bottom of the forks...
Yeah I used the 09 spacers with the 09 axle and everything seems to button up pretty good, except for how the bottom of the forks are slightly tweaked in. I'm away from home atm so haven't been able to go back and have a play but I'm thinking if the 09 yz250f clamps will pair up with the steel frame it'll work.

I originally thought the front wheels may have been different but the oem part numbers for the front wheels on both bikes are exactly the same.
Mr. Robinson wrote:
Yeah, the hub is the same for sure. I'm sure you'll get it figured out.
Yeah I'll sort it out, cheers for your input. Appreciate it
beamer
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beamer 1/1/2021 9:58am
1/1/2021 9:58am Edited Date/Time 1/1/2021 11:39am
beamer wrote:
If it was me I would run the ‘09 triple clamps. I did a similar conversion on a rm250 and run the proper clamps for the...
If it was me I would run the ‘09 triple clamps. I did a similar conversion on a rm250 and run the proper clamps for the forks (‘98 conventionals on a ‘08)
You may be lucky and maybe the steering stems will match up, but not sure.
FWYT wrote:
Hey, I certainly don't mean to hijack this thread, but do you have any stuff posted somewhere about your fork conversion? I am planning to put...
Hey, I certainly don't mean to hijack this thread, but do you have any stuff posted somewhere about your fork conversion? I am planning to put those Showa conventionals on my next build as well and have some questions.
I haven’t , yet but just kind of got started on this during the off season but i did mock it up briefly. Shoot me a DM if you wish, be happy to tell you my experiences up to this point. Plan to collect pics and start a thread at some point hopefully im waiting on Gold Valve kit and proper springs.
1
FWYT
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FWYT 1/1/2021 6:52pm
1/1/2021 6:52pm
beamer wrote:
I haven’t , yet but just kind of got started on this during the off season but i did mock it up briefly. Shoot me a...
I haven’t , yet but just kind of got started on this during the off season but i did mock it up briefly. Shoot me a DM if you wish, be happy to tell you my experiences up to this point. Plan to collect pics and start a thread at some point hopefully im waiting on Gold Valve kit and proper springs.
For some reason, I can't send DMs on Vital. However, I did reply to your thread where you were looking for springs. Maybe we could trade info and Q&A over in that thread?
beamer
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beamer 1/1/2021 7:28pm
1/1/2021 7:28pm
beamer wrote:
I haven’t , yet but just kind of got started on this during the off season but i did mock it up briefly. Shoot me a...
I haven’t , yet but just kind of got started on this during the off season but i did mock it up briefly. Shoot me a DM if you wish, be happy to tell you my experiences up to this point. Plan to collect pics and start a thread at some point hopefully im waiting on Gold Valve kit and proper springs.
FWYT wrote:
For some reason, I can't send DMs on Vital. However, I did reply to your thread where you were looking for springs. Maybe we could trade...
For some reason, I can't send DMs on Vital. However, I did reply to your thread where you were looking for springs. Maybe we could trade info and Q&A over in that thread?
I sent you a dm with my email, let me know if you get it
1

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