2002 YZ250 SSS Conversion

newmason
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Edited Date/Time 6/23/2019 7:48am
Working on the build at the moment, have most of what I need from a 2007 yz250f (Forks and shock) however I have been running into issues with steering stem length. Order clamps off of the fleabay for a 2007 yz250f only to find the stem to be to short. Read that I needed to press the stem out of my 02 and onto the 07 clamp.Tried that but found the IN diameter of the steering stem race to be smaller.

I read on another forum last night, that there are certain years where there were short, medium and long stems. It looks like the stem length on the 2007 yz450f (not the 250f) should be the same length as that of the older yz250. Can anyone confirm?
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6/20/2019 7:08am
To make your swap easy is to get 2004 Yz 250 triple clamps that have the steelframe stops and was first year with 48 mm forks
alexk417
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6/20/2019 9:22am Edited Date/Time 6/20/2019 9:25am
Yup do what he ^ says.

Around the beginning of the year Pro Circuit did the deal of the week on the Yamaha Upper & Lower triple clamps for the 2004 YZ's. I snagged them of course to do the SSS swap on my 2002 YZ125. I used 2011 YZ250F Forks.

You're going to run into issues with the steering stops using the YZ450F Clamps unless you have someone weld larger frame stops, but if you wanted to know a 2007 450 will have the Long Stem that the YZ250's use.

FYI - The bearings for a lot of the Yamahas haven't changed. 96-19 YZ125 & YZ250, 01-19 YZ250F, 03-19 YZ450F all use the same ID/OD bearings.



2
Wycked31
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6/20/2019 9:43am
newmason wrote:
Working on the build at the moment, have most of what I need from a 2007 yz250f (Forks and shock) however I have been running into...
Working on the build at the moment, have most of what I need from a 2007 yz250f (Forks and shock) however I have been running into issues with steering stem length. Order clamps off of the fleabay for a 2007 yz250f only to find the stem to be to short. Read that I needed to press the stem out of my 02 and onto the 07 clamp.Tried that but found the IN diameter of the steering stem race to be smaller.

I read on another forum last night, that there are certain years where there were short, medium and long stems. It looks like the stem length on the 2007 yz450f (not the 250f) should be the same length as that of the older yz250. Can anyone confirm?
I have your set up. RG3 Clamps and a set of 09 YZ250F forks valved to 170lb Intermediate rider. Came off a 03 steel frame

email me chadmgodwin@gmail.com and I can send over pictures. The clamps are $250.00 and the forks (need to take pictures) are $ 700.00

newmason
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6/20/2019 10:28am
I've got everything I need other than the triple clamps. Just had my SSS forks rebuilt and revalved but wanted to make sure that the 2007 yz450f stem was the same length as the yz250. I am aware of the stops and will be welding on the additional material once I get the clamps situated.

The Shop

newmason
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6/20/2019 10:37am
alexk417 wrote:
Yup do what he ^ says. Around the beginning of the year Pro Circuit did the deal of the week on the Yamaha Upper & Lower...
Yup do what he ^ says.

Around the beginning of the year Pro Circuit did the deal of the week on the Yamaha Upper & Lower triple clamps for the 2004 YZ's. I snagged them of course to do the SSS swap on my 2002 YZ125. I used 2011 YZ250F Forks.

You're going to run into issues with the steering stops using the YZ450F Clamps unless you have someone weld larger frame stops, but if you wanted to know a 2007 450 will have the Long Stem that the YZ250's use.

FYI - The bearings for a lot of the Yamahas haven't changed. 96-19 YZ125 & YZ250, 01-19 YZ250F, 03-19 YZ450F all use the same ID/OD bearings.



Dang good snag! To bad they are not the 250 clamps and keep an eye out for me if you see any!
alexk417
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6/20/2019 11:07am
newmason wrote:
Dang good snag! To bad they are not the 250 clamps and keep an eye out for me if you see any!
The only difference is the steering stem length.. PC has the top one on their site, but I'm afraid the bottom is out of stock at the moment.

https://www.procircuit.com/top-clamp-yz125-450f-04-05.html

https://www.procircuit.com/lower-clamp-yz250-04-yz450f-04-05.html

I think the only downfall on going the 2004 clamp route with newer forks is your front wheel might end up off center 1 or 2mm. I ended up removing material from the caliper side wheel spacer.



newmason
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6/20/2019 11:32am
I grabbed 2007 YZ450F triple clamps off ebay knowing that the year has the correct stem length. Other than having to weld the steering stop, I've got the 2007 yz450 axle, spacers and brake. Should work?
6/20/2019 11:46am
newmason wrote:
Dang good snag! To bad they are not the 250 clamps and keep an eye out for me if you see any!
alexk417 wrote:
The only difference is the steering stem length.. PC has the top one on their site, but I'm afraid the bottom is out of stock at...
The only difference is the steering stem length.. PC has the top one on their site, but I'm afraid the bottom is out of stock at the moment.

https://www.procircuit.com/top-clamp-yz125-450f-04-05.html

https://www.procircuit.com/lower-clamp-yz250-04-yz450f-04-05.html

I think the only downfall on going the 2004 clamp route with newer forks is your front wheel might end up off center 1 or 2mm. I ended up removing material from the caliper side wheel spacer.



Yes it's of center and the front disc nearly tutsch caliper bracket so lathe the spacer so disc will center in the bracket 👍
6/20/2019 11:54am
newmason wrote:
I grabbed 2007 YZ450F triple clamps off ebay knowing that the year has the correct stem length. Other than having to weld the steering stop, I've...
I grabbed 2007 YZ450F triple clamps off ebay knowing that the year has the correct stem length. Other than having to weld the steering stop, I've got the 2007 yz450 axle, spacers and brake. Should work?
Then it wont steer out fully , the stops is different on aluframe !
dmm698
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6/20/2019 12:32pm Edited Date/Time 6/20/2019 12:34pm
newmason wrote:
Working on the build at the moment, have most of what I need from a 2007 yz250f (Forks and shock) however I have been running into...
Working on the build at the moment, have most of what I need from a 2007 yz250f (Forks and shock) however I have been running into issues with steering stem length. Order clamps off of the fleabay for a 2007 yz250f only to find the stem to be to short. Read that I needed to press the stem out of my 02 and onto the 07 clamp.Tried that but found the IN diameter of the steering stem race to be smaller.

I read on another forum last night, that there are certain years where there were short, medium and long stems. It looks like the stem length on the 2007 yz450f (not the 250f) should be the same length as that of the older yz250. Can anyone confirm?
Wycked31 wrote:
I have your set up. RG3 Clamps and a set of 09 YZ250F forks valved to 170lb Intermediate rider. Came off a 03 steel frame email...
I have your set up. RG3 Clamps and a set of 09 YZ250F forks valved to 170lb Intermediate rider. Came off a 03 steel frame

email me chadmgodwin@gmail.com and I can send over pictures. The clamps are $250.00 and the forks (need to take pictures) are $ 700.00

I'm envious if you get anywhere near that kind of coin for this setup. The clamps Would bring the 250 to the right buyer but I feel like a lot of guys doing the SSS conversion are super budget conscious and will go with a cheap conversion setup for 100$ and some hasty welding.

I got 450$ cash for my 2013 yz250 2 stroke forks that were all stock with zero hours on a fresh fluid change and brand new bushings. That included the upper and lower clamps. I had kept the stem to run in a set of yz450 clamps I have on my 13 yz now as they had the proper clamping dimensions for some 49mm showa forks i'm running. Threw in a caliper hanger too that was for an OE rotor size, and his 05 caliper mounted right up to the 13 carrier so that whole "new smaller caliper required on newer forks" thing is a wives tale it seems. His was an 05 so luckily I just swapped his stem, and all he needed to do was buy the proper 2013 axle + spacers and not have to deal with wheel offset issues ect.
newmason
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Draper, UT US
6/20/2019 12:37pm
newmason wrote:
I grabbed 2007 YZ450F triple clamps off ebay knowing that the year has the correct stem length. Other than having to weld the steering stop, I've...
I grabbed 2007 YZ450F triple clamps off ebay knowing that the year has the correct stem length. Other than having to weld the steering stop, I've got the 2007 yz450 axle, spacers and brake. Should work?
Then it wont steer out fully , the stops is different on aluframe !
Yea I know, we will be adding material to the steely to allow for correct stoppage. I have found that you have basically two routes, either the grinding down of material on spacers or adding material to the frame for the stops. Even with the PC mounts there doesn’t seem to be a 100% clean bolt and go solution
newmason
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Draper, UT US
6/22/2019 12:05pm
Little update for anyone doing the SSS conversion on a 02-04. So far this is the list of what I have and what I know fits and works:

2002 YZ250 Bike

2006 YZ450F Shock (Direct bolt on and went with the 450F shock only because it came with the 5.5kg spring, saves money on spring cost at Pro-Action use a 250F is you're <190 with gear)
2007 YZ250F SSS Forks (Had them revalved and resprung at Pro-Action)
2007 YZ450F Triple Clamps (This part is important because the 2007 has the LONG steering stem already pressed on)
2007 YZ250F Axle and Spacers. Axle and spacers are specific to the fork and a 450F axle and spacer is different.

Steering stops are close to the edge of the lower clamp and will require some material added (doing this before powder coating frame). After all this I now understand why some people doing the conversion say they bought an entire front end off of a YZ450F and everything bolted right up for a 250, and that is because in 2007 (maybe 2006 too?) the 450F uses the long stem on the triples while the 250F uses the short. Short stem wont work on the 250, and WILL work on the YZ125 SSS Conversion.
newmason
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6/22/2019 5:18pm
alexk417 wrote:
Yup do what he ^ says. Around the beginning of the year Pro Circuit did the deal of the week on the Yamaha Upper & Lower...
Yup do what he ^ says.

Around the beginning of the year Pro Circuit did the deal of the week on the Yamaha Upper & Lower triple clamps for the 2004 YZ's. I snagged them of course to do the SSS swap on my 2002 YZ125. I used 2011 YZ250F Forks.

You're going to run into issues with the steering stops using the YZ450F Clamps unless you have someone weld larger frame stops, but if you wanted to know a 2007 450 will have the Long Stem that the YZ250's use.

FYI - The bearings for a lot of the Yamahas haven't changed. 96-19 YZ125 & YZ250, 01-19 YZ250F, 03-19 YZ450F all use the same ID/OD bearings.



Looks like you're missing one of the washers that goes below the crown nut.
alexk417
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6/22/2019 6:40pm
newmason wrote:
Looks like you're missing one of the washers that goes below the crown nut.
No I just went with the configuration for the 04+ YZ 2-strokes.
newmason
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6/23/2019 7:48am
newmason wrote:
Looks like you're missing one of the washers that goes below the crown nut.
alexk417 wrote:
No I just went with the configuration for the 04+ YZ 2-strokes.
You are correct, looks like Yamaha ditched that second washer in 2004. I wonder why?

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