2005 YZ250 front fork repair / conversion

Oldmanfunk
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Oldmanfunk
Edited Date/Time 10/8/2020 5:39am
Our left upper fork tube was damaged to the point of needing replacement during a recent accident. Unfortunately, the part (#1C3-23136-L0-00) is unavailable from any supplier or eBay. So I researched the upper tube from the 08 ->14 and the part number is different, yet all the washers and seals are the same with the exception of one, diagram #6 -> Washer/oil seal.

Can anyone confirm that if I use the #6 Washer/oil seal along with the upper fork tube from the 08 ->14 that I will be able to assemble my original 05 inner/lower fork tube into the new 09 outer/upper tube?

05 parts brake down --> https://www.motosport.com/oem-parts/yamaha/2005/yz250/front-fork

09 parts brake down --> https://www.motosport.com/oem-parts/yamaha/2009/yz250/front-fork
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FGR01
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FGR01 10/6/2020 7:25am
10/6/2020 7:25am
I think the newer tube will be totally incompatible with your 2005 fork. The 2005 fork was a 1-year unique deal. The inner chamber is different and the chamber/top cap might not even thread into the newer leg. The length may be different also. Your best bet is probably going to be trying to find a good used set of 2006+ forks used.
b8res
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b8res 10/6/2020 10:30am
10/6/2020 10:30am
Oldmanfunk wrote:
Our left upper fork tube was damaged to the point of needing replacement during a recent accident. Unfortunately, the part (#1C3-23136-L0-00) is unavailable from any supplier...
Our left upper fork tube was damaged to the point of needing replacement during a recent accident. Unfortunately, the part (#1C3-23136-L0-00) is unavailable from any supplier or eBay. So I researched the upper tube from the 08 ->14 and the part number is different, yet all the washers and seals are the same with the exception of one, diagram #6 -> Washer/oil seal.

Can anyone confirm that if I use the #6 Washer/oil seal along with the upper fork tube from the 08 ->14 that I will be able to assemble my original 05 inner/lower fork tube into the new 09 outer/upper tube?

05 parts brake down --> https://www.motosport.com/oem-parts/yamaha/2005/yz250/front-fork

09 parts brake down --> https://www.motosport.com/oem-parts/yamaha/2009/yz250/front-fork
I have a set of 05 forks that are in pretty good shape. They came off a 05 YZ125. Have a few different spring as well.

Let me know if your interested.
1
Oldmanfunk
Profile picture for user Oldmanfunk
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Oldmanfunk 10/6/2020 10:40am
10/6/2020 10:40am
Oldmanfunk wrote:
Our left upper fork tube was damaged to the point of needing replacement during a recent accident. Unfortunately, the part (#1C3-23136-L0-00) is unavailable from any supplier...
Our left upper fork tube was damaged to the point of needing replacement during a recent accident. Unfortunately, the part (#1C3-23136-L0-00) is unavailable from any supplier or eBay. So I researched the upper tube from the 08 ->14 and the part number is different, yet all the washers and seals are the same with the exception of one, diagram #6 -> Washer/oil seal.

Can anyone confirm that if I use the #6 Washer/oil seal along with the upper fork tube from the 08 ->14 that I will be able to assemble my original 05 inner/lower fork tube into the new 09 outer/upper tube?

05 parts brake down --> https://www.motosport.com/oem-parts/yamaha/2005/yz250/front-fork

09 parts brake down --> https://www.motosport.com/oem-parts/yamaha/2009/yz250/front-fork
b8res wrote:
I have a set of 05 forks that are in pretty good shape. They came off a 05 YZ125. Have a few different spring as well...
I have a set of 05 forks that are in pretty good shape. They came off a 05 YZ125. Have a few different spring as well.

Let me know if your interested.
They don't seem to be the same set up looking at part numbers. The upper/outer tube is the same but that's about it.



What say you


YZ125 --> https://www.motosport.com/oem-parts/yamaha/2005/yz125/front-fork

YZ250 --> https://www.motosport.com/oem-parts/yamaha/2005/yz250/front-fork
FWYT
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FWYT 10/6/2020 10:41am
10/6/2020 10:41am
b8res wrote:
I have a set of 05 forks that are in pretty good shape. They came off a 05 YZ125. Have a few different spring as well...
I have a set of 05 forks that are in pretty good shape. They came off a 05 YZ125. Have a few different spring as well.

Let me know if your interested.
Was going to say that probably the easiest, cheapest fix is just picking up a set of used '05 forks somewhere.
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HackMan162
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HackMan162 10/7/2020 9:05am
10/7/2020 9:05am
The BEST fix is to find a set of 06->on SSS forks.
mwssquad827
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mwssquad827 10/7/2020 9:13am
10/7/2020 9:13am
HackMan162 wrote:
The BEST fix is to find a set of 06->on SSS forks.
This!! If your going to buy forks..
Oldmanfunk
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Oldmanfunk 10/8/2020 5:39am
10/8/2020 5:39am
We ended up using a new 08-> 14 outer tube and only needed to substitute the #6 washer/oil seal with the one that corresponded with that year tube. It was the only part that was different in that stack of seals and washers. Oddly enough the part is on national backorder, so I had a machinist friend of mine create one on a lathe. Bada-Boom were back in business...

What a major PIA for such a straight forward repair


BTW, he also machined an octagon socket needed to disassemble the forks. Let me know if you need one, he'd be happy to replicate it for a fair price.


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