USD forks for the Dakar

Dansin

Dansin

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I almost can't believe I'm even contemplating it. :blast I know there's a few on here that have done it so any words of wisdom? I've started wading through the 187 page thread on adv rider but losing the will to live. :D If anyone can point me towards a definitive guide I'd be extremely grateful. :thumb2
 
Dunno what your on about :augie

IMG6048-XL.jpg


46mm yz forks and a lower guard from the f800gs with the stock dak front wheel, abs still works too :D

About a week ago I'd have said that there is no 'definitive' guide. One is starting to come together here Best and cheapest bet is to do the yz fork mod with a set of 46mm forks.

the easiest route by far is to take the whole front end of a yz and fit it to the bike, inc front wheel and caliper. A downside to that route is that you loose the abs (if you have it) and the front brake disc is smaller and thinner than the BMW disc.

I went with fitting the BMW wheel to the yz forks, kept the abs too. It's pretty much buy parts and fit. apart from the ignition bracket which does require some work. I have a couple of drawings which may help with that. There is a couple of companies over in the states included in that link, one does the parts needed to fit the BMW wheel and brake caliper, the other does the revalve and respring of the forks.
 
rc mad said:
46mm yz forks and a lower guard from the f800gs with the stock dak front wheel, abs still works too :D

About a week ago I'd have said that there is no 'definitive' guide. One is starting to come together here Best and cheapest bet is to do the yz fork mod with a set of 46mm forks.

the easiest route by far is to take the whole front end of a yz and fit it to the bike, inc front wheel and caliper. A downside to that route is that you loose the abs (if you have it) and the front brake disc is smaller and thinner than the BMW disc.

I went with fitting the BMW wheel to the yz forks, kept the abs too. It's pretty much buy parts and fit. apart from the ignition bracket which does require some work. I have a couple of drawings which may help with that. There is a couple of companies over in the states included in that link, one does the parts needed to fit the BMW wheel and brake caliper, the other does the revalve and respring of the forks.
Click to expand...

Thanks for the info, hadn't found that site before. I'd guessed the Yamaha forks would be easier to achieve than the KTM route. Have you had yours revalved and resprung? A few of the conversions on ADV Rider seem to have left them as stock.

No ABS on mine so not an issue using the whole of the Yamaha front end. If it does need the Dakar wheel, disk and calliper, I can always do that at a later date. Did you source any parts from the States or have you had all of the work done over here?
 
Dansin said:
It does look great but the Yamaha fork conversion can be done without all of the machining that the KTM conversion requires.
Click to expand...

it really isnt a big deal ,u s d !!get a front end off a moto x or enduro bikes..... check out berts te 630RR on rallymoto site dont have to get anything from the states, we make all our own stuff billet yokes too ,,,,,,,,,,,,,moly
 
Get a complete front end is my advice. I would try and find a KTM 640 ADV. Then find a way to raise the rear. Be prepared to spend some serious bucks.
 
Dansin said:
Thanks for the info, hadn't found that site before. I'd guessed the Yamaha forks would be easier to achieve than the KTM route. Have you had yours revalved and resprung? A few of the conversions on ADV Rider seem to have left them as stock.

No ABS on mine so not an issue using the whole of the Yamaha front end. If it does need the Dakar wheel, disk and calliper, I can always do that at a later date. Did you source any parts from the States or have you had all of the work done over here?
Click to expand...

Initially i left them as they came, they are an improvement over the stock set-up but to get the best out of them requires a re-valve and different springs. I went with progressive weight springs. Any place in the UK should be able to do a re-valve to suit you and the bike.

As for it costing loads, for the improvement it's worth it.. I spent around £350 total including the forks. Helps that I got the axle made free and did most of the other parts myself. biggest spend was the calliper hanger but that is not really needed if you can make an adapter plate to adapt the stock hanger to the forks.

If you was to buy yz everything it's even cheaper to do. Plus you'll gain on selling off the stock front end.

btw you really need to pm me :thumb
 
moly said:
it really isnt a big deal ,u s d !!get a front end off a moto x or enduro bikes..... check out berts te 630RR on rallymoto site dont have to get anything from the states, we make all our own stuff billet yokes too ,,,,,,,,,,,,,moly
Click to expand...

I hope you're right Moly! Looking to get it done for the rally sprint in April. That way I can get you to help me set it up... :D Hopefully it will help with a few less over the handlebar moments. :eek:
 
I say again, you will need to raise the rear of the bike. RC made some very nice dog bones for us and that is how I have gone. Otherwise you will be bottoming out before the forks reach bottom limit
 
komatias said:
I say again, you will need to raise the rear of the bike. RC made some very nice dog bones for us and that is how I have gone. Otherwise you will be bottoming out before the forks reach bottom limit
Click to expand...

Noted. I'm speaking to rc via pm to hopefully get the relevant drawings from him. I also wondered about trying to lose all of the scaffold under the sump to gain a bit of clearance. I reckon there's a good chunk of space there if I can fabricate a carbon kevlar sump guard.
 
I'll sort the drawings out later this evening. Off to the gym now :D

Dansin, if you buy the tt sump guard with the tool storage it does move the skid plate upwards and gives more clearance as it uses a new subframe, notmybiike on adv ditched the subframe altogether with no issues.
 
Dansin said:
I hope you're right Moly! Looking to get it done for the rally sprint in April. That way I can get you to help me set it up... :D Hopefully it will help with a few less over the handlebar moments. :eek:
Click to expand...

Yep no probs we can sort it :beerjug:
 
Conversion is underway

I've now got a YZF426 triple which is in great condition. I've also got some KYB 46mm forks from a YZF250 which I need to get resprung and revalved for my and my bikes weight.

The intention is to retain the GS front wheel, disk and brake caliper so new parts need manufacturing. Thanks to RC Mad and John Aero I have the dimensions to make various parts. The ignition mount is being laser cut from 3mm stainless steel. I have a mate who is sorting that for me. I've started modelling the remainder of the parts to pass on to an engineering company. I've got the caliper mount to finish off.

Rear link to lift the rear by 1".

<img src="http://farm8.staticflickr.com/7164/6839911179_c69f7415c5_b.jpg" width="1024" height="480" alt="Lift link"></a>

New front axle.

<img src="http://farm8.staticflickr.com/7152/6839910521_37656acc33_b.jpg" width="1024" height="475" alt="Axle parts 1"></a>

Axle spacer and bolt.

<img src="http://farm8.staticflickr.com/7013/6839910789_267a7c4556_b.jpg" width="1024" height="475" alt="Axle parts 2"></a>
 
mikeTR said:
Good Progress Daniel :thumb2

Which design/style of Ignition mount have you decided to go for?
Click to expand...

A combination of RC's design and another one from the thread over on ADV rider. I'm not 100% sure I'll use all 3 parts but as they're only flat stainless I can modify them if needed.

<img src="http://farm8.staticflickr.com/7157/6841256171_a9efb2c457_b.jpg" width="1024" height="475" alt="Ignition mount 1"></a>

komatias said:
who is doing your resping/valve job?
Click to expand...

Hadn't got that far. I was going to speak to Racespec in Tewkesbury as they're pretty much the closest place to me. Unless you have someone you can recommend?

I'm not sure whether I need to bother with progressive springs. I realise yours is not a KYB conversion but did you use progressive or stock springs?
 
Nippy Normans supply Touratech, Wunderlich, Desert Fox and many other makes of accessories.
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