Posts
70
Joined
9/26/2015
Location
Scottsdale, AZ
US
Edited Date/Time
4/14/2019 12:20pm
Hey guys, currently rebuilding my 06 yz 250 and thinking about getting another bike down the road. Buddy has an 03 yz 250 I got him to buy and really liked how it felt. Im interested in getting an 02-04 yz and eventually switching the forks and shock. Just wondering what it would entail to swap SSS forks over and if i need to get a 06+ shock and what parts will need to be acquired (different triple clams, brake system, etc.) including, if possible, how much it costs. Also to note if its just worthwhile to do a revolve and springs instead. All knowledge is appreciated
Also you will need to press out the old steering stem and press it to the new triples. Overall really easy project
Just something to think about...
The Shop
Was slightly easier for me as it’s an 04 so the different clamps etc..
This is what I used -
-2004 PC triple clamps (can use standard 04 clamps)
- 2009 YZF250 Forks
- 2009 YZF250 Front wheel, axle and spacers
- 2010-2013 YZF250 Rear shock (just swap the lower spring collar from your standard shock on to the YZF shock and it bolts straight in)
- CRF450 Front brake caliper
- CRF450 Front brake master cylinder
- 2009 YZF250 Caliper bracket
- YZ250 Brake Line
The brake upgrades are optional but I’d definitely recommend them as it’s a massive improvement from the brakes the YZ250 comes with
Can’t comment on the standard YZF shock though, although kit shocks for YZF’s are a lot easier to find than they are for the YZ’s so it’s good to know they’re interchangeable
The very first one was my own 01 YZ.
So...here's what you need to know.
1. Nearly all shocks in the YZ 46mm group are a drop-in swap. The only exception would be the later model shocks where the N2 reservoir is not parallel with the shock body. That said, there isn't much advantage with swapping the shock. Tuning is more important. In other words, you can make a 2001 shock work just as good as a 2009.
2. Not all SSS forks are the same. They have different lengths and different upper tube sizes, (ODs) especially 2010 and beyond. This isn't a big deal but just keep in mind that you'll need to watch for this. That said, they are basically the same fork from 2006 to 2019. Oh...the 05 is the KYB AOS fork - a twin chamber fork, but very VERY different than the 06-19 fork.
3. Keep in mind that there are different brake caliper mounts. The biggest difference is the earlier wide mount, and the narrower mounts. Again, not a big deal but watch for it.
4. Also consider things like fork guards. The designs got better in later models.
5. When purchasing something used on eBay it's "buyer beware". Some forks and shocks are in great shape, others are beat to sh*t. The good news is that KYB parts are super cheap and easy to get.
6. Don't buy ANYTHING that has a color change. Most of these have gone through a process where they strip the factory anodizing off and then anodize them a different color. This process appears to strip off the anti-friction coating on the inside (shock and fork tubes) even when sealed off.
7. It's fairly common for the lugs to come lose on KYB forks. Test for it. They can often be repaired but if they have been ran loose for too long, the treads will be trashed and the tube and lug will need to be replaced.
8. It's very common for KYB SS forks to have cracked free pistons. If they don't, the pistons will most likely be significantly degraded. Replace them with aluminum units. It's also fairly common for the damping rods to lose their Type II coating, taking out the seal and bushing with it.
9. Don't trust any suspension you buy. Take it apart and do a full inspection. And measure the spring rate as well as the length. Make sure you have the right length for your fork, (there are 5 different KYB 48mm fork spring lengths). Keep in mind that some people do some stupid stuff sometimes and you don't want to risk your health. Check EVERYTHING!!
10. You may have to create a new steering lock on your steel frame to work with a new clamp. See photo.
And I'll add this...the 48mm KYB open bath forks that came on the WRs, starting in 06, when tuned correctly, are a better fork than the SSS. Heavier, but better. Almost no degradation, which is more relevant in an off-road application.
But they don't seem as cool.
You may be better off using the standard YZ brake line
Overall it really is a simple process, even if you would have to do the triple clamp stem swap for a 2002 or 2003.
Here was my experience with my 2004 YZ 125 build over the winter.
Parts I used from my 2004:
Triple Clamps
Front Wheel
Master Cylinder
Caliper
Parts taken from a 2007 yz 250f (or similar years that shared part numbers) :
2007 yz250f Forks
Axle and Wheel Spacers
Fork Guards
Brake Line
Brake Caliper Mounting Bracket
One extra thing that I did that I don't hear a lot of people doing....... I took 1mm of material off the brake side wheel spacer (using a lathe). From my research, I found that in 2006, Yamaha spread their triple clamps 1mm wider on each side. They then made up for this down at the wheel by casting the fork lugs in 1mm. So essentially, by using the 2007 forks (with the lugs cast in 1mm) and the 2004 triple clamps (not widened), the wheel ends up getting offset an extra mm away from the brake side. By taking a mm off the brake side spacer, the wheel is then centered.
Honestly this is probably something that you could just ignore... I can't imagine it would make much of a difference if the wheel was off center by 1mm. I doubt that you would be able to feel it on the track. But, I just did it for peace of mind...
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