When I originally constructed the LegoBike from a stock R80G/S I fitted a Yamaha DTR125 front end to it.
You may think that it wouldn`t be a wise thing to do,but it had 41mm forks and the small disc and caliper was actually better than the stock Airhead one!
All the mod required was to reduce the diameter of the bottom of the stem by 2mm (enabling stock size headbearings to be used) and fit a spacer under the top yoke.
I also fitted Africa Twin spec Progressive fork springs with 25mm spacers and all was well.
Although the DTR brake was better than the Airhead one when solo,it wasn`t up to the job when loaded or two up ..... and damn well scary after riding an 1100GS most of the time and then getting on the LegoBike.
So...I acquired a complete Yamaha XTZ750 Super Tenere twin disc front end off a fellow UKGSer ( cheers Garry
) and shut myself in the garage.
This time,the mod needed more work.
The XTZ stem was too large in diameter at both ends,and also too long.
A simple 'fix' would have been to swap stems with the DTR bottom yoke,but I wanted to keep that front end complete for future projects.
So it was decided to make a copy of the modded DTR stem and fit it to the XTZ bottom yoke.
This is where my job pays off...access to metal stock and machine shops
The XTZ stem took 22 tons of pressure on the press to remove it
The modded DTR stem was measured up and a suitable piece of stainless bar was machined to match in all dimensions,including copying the adjuster nut threads. This was then pressed back into the XTZ bottom yoke...and just to play it safe,a grubscrew was also fitted to secure the stem.
Brand new taper rollers went on a treat,and I fitted the front end at the weekend....it was just like assembling a kit
I`ve overhauled the calipers and fitted brand new EBC discs.
There`s still a little bit left to do,but here`s some pics.
You may think that it wouldn`t be a wise thing to do,but it had 41mm forks and the small disc and caliper was actually better than the stock Airhead one!
All the mod required was to reduce the diameter of the bottom of the stem by 2mm (enabling stock size headbearings to be used) and fit a spacer under the top yoke.
I also fitted Africa Twin spec Progressive fork springs with 25mm spacers and all was well.
Although the DTR brake was better than the Airhead one when solo,it wasn`t up to the job when loaded or two up ..... and damn well scary after riding an 1100GS most of the time and then getting on the LegoBike.
So...I acquired a complete Yamaha XTZ750 Super Tenere twin disc front end off a fellow UKGSer ( cheers Garry
) and shut myself in the garage.This time,the mod needed more work.
The XTZ stem was too large in diameter at both ends,and also too long.
A simple 'fix' would have been to swap stems with the DTR bottom yoke,but I wanted to keep that front end complete for future projects.
So it was decided to make a copy of the modded DTR stem and fit it to the XTZ bottom yoke.
This is where my job pays off...access to metal stock and machine shops
The XTZ stem took 22 tons of pressure on the press to remove it
The modded DTR stem was measured up and a suitable piece of stainless bar was machined to match in all dimensions,including copying the adjuster nut threads. This was then pressed back into the XTZ bottom yoke...and just to play it safe,a grubscrew was also fitted to secure the stem.
Brand new taper rollers went on a treat,and I fitted the front end at the weekend....it was just like assembling a kit
I`ve overhauled the calipers and fitted brand new EBC discs.
There`s still a little bit left to do,but here`s some pics.
