Welcome, Guest. Please Login or Register

Author Topic: TR650 fork conversion - YZ/WR  (Read 740 times)

0 Members and 1 Guest are viewing this topic.

Offline Aquatic

  • Senior Member
  • ***
  • Bike: BMW F650GS / Dakar
    Location: Australia
  • Posts: 1,903
  • Sunshine Coast, Queensland, Australia
    • Ratel Engineering Design
TR650 fork conversion - YZ/WR
« on: June 19, 2016, 07:35:10 am »
Mike Malloy(here in Aus) contacted me and asked if I could help him with the WR fork conversion on his TR650.

After some discussion we decided to get his bike into my workshop to at least measure it up and check what I would need to do to make my BMW conversion work on the Terra.
Due to circumstances, mike's bike was off the road and in need of repairs. So His mate Ralph's bike was brought in



So I took measurements and did some wheel swapping. Put the Husky wheel on my YZ converted Dakar. And what do you know, no special parts to make. I only needed to make the axle 5mm longer.
The Terra has a 195mm fork pitch and the yamaha triples have a 190mm offset.
Could it real be this easy? No not really!

The Terra and KYB forks have the same diametre at the top clamp. But at the bottom clamp the Terra forks measure Ř58mm and the KYB forks Ř58.4mm.
Only 1 way fix this. Machine out the lower clamp to the correct size.

All was put on hold for a bit until Mike's forks and bike made it to my workshop.
Ralph's bikes left with a dire needs for headstock bearings.

What i did do while waiting was machine up the new axle kits.
Thai is what is needed

Axle and nut, Non ABS spacer and a caliper hanger.

Once all the goodies arrived it was time to strip Mike's bike down and start the conversion.

Old and new


One thing I did notice was that Mike needed some headstock bearings as well.
Stripped them out and found this. The wear is clearly visible


And also something that bothers me. The bearing locations have been powder coated? IMHO this is not the way it should be.

I removed the powder coating before re assembly.

Next was to machine the lower clamp
setup

Boring head ready to go


[MEDIA=youtube]ZXFKRwcIN5c[/MEDIA]

Machining done it was time to put it all back together.
New bearings greased up and in, lower clamp and spindle all tightened up and ready

The manual says tighten to 19Nm. Not having a driver for the ring nut I tightened up by feel. Never had a problem with this way in the past.

Because of the nature of Mike's cockpit setup, the headlight shroud had to go on at the same time as the top clamp.
Top clamp on, shroud on, KYB fork in place.

Top clamp nut tightened to 80Nm
Fork tube clamp bolts to 19Nm

Time to install the front wheel

Everything lines up just sweet



Next is the brakes

Strip down the OEM caliper hanger

Transfer the pin grommet and plate to the Ratel hanger

Put it together

And install on the bike. The disc is perfectly spaced in the hanger


And there you have it, all together


As you can see, you wouldn't even notice what was done unless you were told or noticed the colour differences.

I'm not sure if the OEM brake line would work with the extra length forks. Mike already had an aftermarket brake line installed.

Mike's headlight shroud made things a little difficult, but I would say that the whole operation can be done in a day. That is if you have a machine ready to cut the lower clamp.

Feel free to ask questions
The conundrum that is life...
You have to be absolutely smashed to have the guts to attempt it,
But perfectly sober to achieve any success!
 

Offline Oubones

  • Senior Member
  • ***
  • Bike: BMW F650GS / Dakar
    Location: Kwazulu Natal
  • Posts: 3,427
  • Thanked: 589 times
Re: TR650 fork conversion - YZ/WR
« Reply #1 on: June 19, 2016, 07:44:10 am »
 :thumleft: Now that is neatly done!
Thanks for posting!
Dakar 650
SR 500
 

Offline chopperpilot

  • Afrikaans...Dis my taal! Engels...Dit verstaan ek ook!
  • Forum Whore
  • ****
  • Bike: KTM 990 Adventure
    Location: Mpumalanga
  • Posts: 7,677
  • Thanked: 234 times
  • "Jack of all Trades... Master of Some."
Re: TR650 fork conversion - YZ/WR
« Reply #2 on: June 19, 2016, 07:59:45 am »
Super neat! Well done!👍


Sent from my iPad using Tapatalk
Current Bikes : KTM 990 R, KTM 500 XCW

End of an Era : Suzuki DR 650 SE, Husqvarna 610 TE
 

Offline BiG DoM

  • A Grahamstown Greyhound!
  • Moderator
  • Bachelor Dog
  • *****
  • Bike: BMW R1200GS HP2
    Location: Eastern Cape
  • Posts: 18,075
  • Thanked: 275 times
  • License Plates: GSpot EC and HUSKY EC
Re: TR650 fork conversion - YZ/WR
« Reply #3 on: June 19, 2016, 08:39:18 am »
Very nice and many swear the KYB is better than WP etc. It will be interesting if he feels a difference in handling (other than the forks) as 5mm triple angle can be quite a bit but maybe the longer forks will accommodate.
"Love is the feeling you get when you like something as much as your motorcycle" - Hunter S. Thompson

Scoots: BMW HP2E  Husky 701E  BMW R100S

 :ricky:
 

Offline BiG DoM

  • A Grahamstown Greyhound!
  • Moderator
  • Bachelor Dog
  • *****
  • Bike: BMW R1200GS HP2
    Location: Eastern Cape
  • Posts: 18,075
  • Thanked: 275 times
  • License Plates: GSpot EC and HUSKY EC
Re: TR650 fork conversion - YZ/WR
« Reply #4 on: June 19, 2016, 08:40:19 am »
Very nice and many swear the KYB is better than WP etc. It will be interesting if he feels a difference in handling (other than the forks) as 5mm triple angle can be quite a bit but maybe the longer forks will accommodate. Now if you could add that 6th gear …  :lol8:
"Love is the feeling you get when you like something as much as your motorcycle" - Hunter S. Thompson

Scoots: BMW HP2E  Husky 701E  BMW R100S

 :ricky:
 

Online sidetrack

  • Bachelor Dog
  • *****
  • Bike: Yamaha XT 660 Z
    Location: Gauteng
  • Posts: 13,362
  • Thanked: 374 times
  • T7 dreamin’ ....
Re: TR650 fork conversion - YZ/WR
« Reply #5 on: June 19, 2016, 07:11:45 pm »
Fairing also transforms bike  :thumleft: Bigdom I rode a YZ with KYB SSS and it performed much better than any WP I had before.
Little by little, one travels far
J.R.R Tolkien

Help make the TSAT a reality
http://www.wilddog.za.net/forum/index.php?topic=241580.msg4325284#msg4325284