A Little Summer Suspension Project

[twowheels]

I'm loving the 250RR I had as a demo bike this summer, especially after I tuned the Sachs forks. Still I have to admit I had suspension envy when the Racing Editions were introduced with those sexy red-legged Marzocchi 48s. I happened to have access to a new set of Kayaba SSS forks from a 2012 WR450, so after a little (OK, a lot of) machine work creating an upper triple and fabbing up wheel spacers, here's the result.

[Hawkeye]

You have the design of that clamp? My riding buddy runs his own tool and die shop, I also just happen to have a WR450F and a YZ250 in my garage...

[twowheels]

You have the design of that clamp? My riding buddy runs his own tool and die shop, I also just happen to have a WR450F and a YZ250 in my garage...

In an effort to remain as close to stock-looking as possible I copied almost all of the dimensions and features from the OE clamp. The most notable difference is the upper tube diameter - 56mm for the KYBs instead of 53.6 for the Sachs and the Marzocchi 48s.

I decided that I wanted to use the Beta 260mm rotor and black wheel as well, which meant I needed sleeves for the axle spacers and a caliper hanger bracket.

[hawaiidirtrider]

So what's the result? Is it better? the same? what kind of settings? etc.. What's wrong with stock?

[twowheels]

So what's the result? Is it better? the same? what kind of settings? etc.. What's wrong with stock?

I ran the WR forks straight up for a month or so before tearing into them for routine maintenance and a little tuning. Since they came off of a big 4 stroke they were over-sprung, so I dropped from the stock 0.46 to a set of 0.44 springs. At the same time I was looking for a little less progression in the compression damping so the stock IC spring got dropped a rate as well. Fluid level was set down 10cc as well.

I'm pretty pleased with that set up but will have to take it to my normal test spot and not judge solely on the last hare scrambles - that course has a way of beating you up no matter what.

Stock was fine (after a re-valve) but there is no doubt that twin or closed chamber forks have more potential and tuning range than open chamber legs. I'm loving the 250 so I didn't want to kick it to the curb when the 300 Racing Edition was introduced. That left me with three options. One, I could have lived with the Sachs set-up I had developed. Two, I could have popped a set of those gorgeous red Marzocchis on the front. Third -and the option I chose in order to bolster the suspension tuning and custom fabrication parts of my business - was to design/machine a new top triple clamp and various bits in order to fit the KYBs. I guess you could say the challenge was too great to turn down

[Darkside]

Third -and the option I chose in order to bolster the suspension tuning and custom fabrication parts of my business - was to design/machine a new top triple clamp and various bits in order to fit the KYBs. I guess you could say the challenge was too great to turn down

Does this mean you'll be offering kits to do this this?

[twowheels]

Third -and the option I chose in order to bolster the suspension tuning and custom fabrication parts of my business - was to design/machine a new top triple clamp and various bits in order to fit the KYBs. I guess you could say the challenge was too great to turn down

Does this mean you'll be offering kits to do this this?

At this point it was a one-off to see if it could be done. It can. I'm testing the waters on commercialization.

[hawaiidirtrider]

Just so you know there's Emig racing with a clamp.. The offsett is different I think though. ..and of course you could check with BRP to see if their clamps already cross over for fit..

http://www.emigracing.com/

[twowheels]

Just so you know there's Emig racing with a clamp.. The offsett is different I think though. ..and of course you could check with BRP to see if their clamps already cross over for fit..

http://www.emigracing.com/

I'll contact Emig and see if they would make the clamp, but you're correct in assuming the 2T offset (20mm) is different than what is shown on their site.

BRP has a folder for the new Betas but no contents.