View Full Version : KTM adventure 950S forks on a Dakar..I dun it

27-06-08, 09:25
Ok here goes. First off you need to turn down the axel to take the BMW bearings (28mm bore). The axel is in imperial but very close to 29mm. The tollerances are critical on the turning as the lower bearing is on a transition fit to keep it from spining round the axel. Ideally the top one should be but too it aint. Any competent machinist will be able to do it though. Don't have a correct drawing of the mod as I did it on the fly myself.
<a href="http://picasaweb.google.co.uk/g.konstantinidis/USDForkMODOnF650GSDakar/photo#5216274102995660754"><img src="http://lh4.ggpht.com/g.konstantinidis/SGPtqOAgL9I/AAAAAAAAAEg/q9A0mEfNrgQ/s800/DSC00313.JPG" /></a>
The stock ignition lock will fit into the KTM holes with some modification. I used a dremel to do the milling operation.
<a href="http://picasaweb.google.co.uk/g.konstantinidis/USDForkMODOnF650GSDakar/photo#5216273933926701346"><img src="http://lh5.ggpht.com/g.konstantinidis/SGPtgYLUmSI/AAAAAAAAAD0/mU-xUd9-1VI/s800/DSC00308.JPG" /></a>
The offset of the adventure forks is such that it just clears the front sub frame but I will be trimming it to be sure.

Bear in mind that you will need a new caliper, or special mounting bracket for the caliper because the BMW one is not compatible with the pins on the KTM calipers. Picked one up on ebay with a supermoto bracket for cheap. Wanted a 320mm disc on the front you see. You will also need a new brake line because of the extra length.

<a href="http://picasaweb.google.co.uk/g.konstantinidis/USDForkMODOnF650GSDakar/photo#5216274012214436402"><img src="http://lh3.ggpht.com/g.konstantinidis/SGPtk70kojI/AAAAAAAAAEI/P8lajXoMkoE/s800/DSC00310.JPG" /></a>

I will be putting the original front fender on as it is easy to do so and I want the bike to look like it did. To do this I took the lower yoke, heated the plastic of the fender up and pressed it into the lower yoke. Some clever measuring and drilling has allowed me to match the fender up with the holes on the KTM yoke. Will be fitting tonight. The horn will be cleverly placed in its original position. The black plastic plate that sit on the yokes above the fender that a cable is passed through is still under thought.
<a href="http://picasaweb.google.co.uk/g.konstantinidis/USDForkMODOnF650GSDakar/photo#5216273968684265074"><img src="http://lh3.ggpht.com/g.konstantinidis/SGPtiZqK7nI/AAAAAAAAAEA/lqFvFK-JNZE/s800/DSC00309.JPG" /></a>
Another part I would suggest you get is, a Husaberg or KTM bearing cover. These are better than the BMW ones as they are bigger and cover the whole bearing and bearing seat.

What I need to sort out is the steering stops. The KTM system don't work but I dont want to drill hole in the yokes or frame so will give it some thought.

Oh and that copper slip is there from previously...

27-06-08, 10:21
Great job fella, well worth the effort :thumb

Keep us up to date with the progress, and of course the all important "MONEY" shot (when it's all complete).

Sergeant Pluck
27-06-08, 11:04
Nice job - now all you need is a KTM adventure 950S from the forks backwards and you'll have a great bike :thumb :D

27-06-08, 11:18

He rides a Triumph :augie:augie:augie:augie

Sergeant Pluck
27-06-08, 11:40

He rides a Triumph :augie:augie:augie:augie


Was only joking. +1 on the 'money shot' when you're all done :thumb


27-06-08, 11:50
To date:

Disc+bolts 75 new
Husaberg Wheel 50 used
Caliper+mount 25 used
Forks + yokes 300 nearly new
SXF yokes only used their axle 35 new (ebay)
Bearings $21 (I aint telling :augie) new
Bearing covers 2
Adventure brake line 20 used
Spacers 8

another say 30 for various tools, such as a hydraulic jack to make a hydraulic press + t-section

brings me to : 566 total
Time spent....3 months of planning+buying 2 weekends and an evening of putting it all together.