Front End Forks Swap YZ

[kwb377]

Forgot to specify...which rear spring did you go with? I'm looking to swap mine for an RT...

Thanks!

 

[Rickyme]

Im really keen on doing this - thanks for posting.
id thought to go a new racetech shock with the kool adjustable preload.

 

[Shawn Johnson]

Im really keen on doing this - thanks for posting.
id thought to go a new racetech shock with the kool adjustable preload.

If you run into any problems let me know and I will give you more detailed instructions.

 

[Rickyme]

Ive been reading the BMW 650 conversion thread over at ADV and they use the triple clamps off the YZ also . I assumed it was because the original BMW forks are thinner than 46mm but on checking the Terra specs it states 48mm forks on the terra.
Justa wondering how the 46mm yammie tubes are a tight fit in the terra triple clamps.
Or is the measurement not outside of tube?
Also I cant see any indication of speedo reading off the front wheel, am I correct in assuming it reads from gearbox or some where else?
Cheers for any thoughts out there

 

[Shawn Johnson]

Ive been reading the BMW 650 conversion thread over at ADV and they use the triple clamps off the YZ also . I assumed it was because the original BMW forks are thinner than 46mm but on checking the Terra specs it states 48mm forks on the terra.
Justa wondering how the 46mm yammie tubes are a tight fit in the terra triple clamps.
Or is the measurement not outside of tube?
Also I cant see any indication of speedo reading off the front wheel, am I correct in assuming it reads from gearbox or some where else?
Cheers for any thoughts out there

Installing the YZ forks are a tight fit. I had to spread the triple clamps with 2 screwdrivers. One screw-driver for the upper clamp and one screw-driver for the lower clamp. I attached a picture to show you how it did it. You have to twist the forks while pushing the up.
The speedometer pickup is on the back wheel.

 

[Shawn Johnson]

 

[Shawn Johnson]

It's not the easyist thing to do because the screw drivers always want to pop out. Two people would help while installing the forks.

 

[WayneC]

Speedo is off the rear wheel not the front, you need to read the F800GS and G650X threads at Advrider to understand your yoke dimensions

 

[Johnn]

Did a rough measure using verniers on my Strada which I believe is the same as the Terra.
OD of the top of fork is 54mm at the lower triple clamp it is 58mm. The tube at the bottom (the moving part) is just under 46mm. You would have to match the ID diameter of the triple clamps. Not much scope for reaming out the ID of the triple clamps if you wanted to go that way.

 

[Rickyme]

ah so itd the bottom tube measurement, thanks Johnn.

 

[duibhceK]

Also I cant see any indication of speedo reading off the front wheel, am I correct in assuming it reads from gearbox or some where else?

speed is read off the rear ABS ring.

 

[Rickyme]

It's not the easyist thing to do because the screw drivers always want to pop out. Two people would help while installing the forks.

Thanks for that Shawn - time to look for some parts, they look to cost a bit more over here but cost of shipping makes it about the same.Did the conversion raise your bike much? I have an SW Motech centre stand that I love.
Also as far as the race tech spring in your rear shock was that to just firm it up or to raise the back ?
Cheers

 

[Shawn Johnson]

It conversion didn't raise the bike at all.
The stock forks are 34" long. and the YZ forks are 36" long. The YZ forks have 1/4" more sag than the stock forks.
I have the YZ forks 1 3/4" above the top triple clamp to compensate for the longer fork and the 1/4" more sag.
I had the heavier rear spring installed when I first got the bike becuase I weigh 220 lbs, it retains the stock height.

 

[Shawn Johnson]

One more note: You will have to cut the front brake light wire and install new crimp plugs to fit on the 2008 and up Kawasaki KLR 650 master cylinder.

 

[WayneC]

Shawn, they are not my parts, they are made by Aquatic, the original swap was worked out by in the US and the first batches of parts made in the US

The YZ brake you are using is not up to the needs of the Terra or the 650GS in repeated use situations, that was one of the concerns of the originator of the swap

 

[Rickyme]

Done!
forks, complete wheel , caliper off a 2001 YZ250f in the post tomorrow
look to be in pretty good nick $750 aud delivered,
Also KLR master cylinder on the way does the KLR brake line work with the YZ caliper or the other way round?

 

[Shawn Johnson]

Use the YZ Caliper and YZ hose with the KLR cylinder. If you look at the past pictures I have already posted you will see that. I also have attached a picture of the wires connected to KLR cylinder.

 

[Shawn Johnson]

Done!
forks, complete wheel , caliper off a 2001 YZ250f in the post tomorrow
look to be in pretty good nick $750 aud delivered,
Also KLR master cylinder on the way does the KLR brake line work with the YZ caliper or the other way round?

Don't forget you need the forks guards with guides US Ebay item #351221843984. I attached a picture.
Also you will need an extra spacer for the axle. They sell in a set but you only need one cut down to 1/2" inch. I attached a picture of an Ebay item. I also showed a picture of the spacer in a previous post.

 

[Shawn Johnson]

I swapped out the forks, wheel, brake system on my 2013 Terra 650. This is a massive improvement over the stock forks.
The forks that will fit are 1999 thru 2002 46mm. I used a pair of 2002 YZ426F forks. The forks will slip right into the stock triple clamps. It is a tight fit, you will need to spread them open a bit. I used a couple of large screw drivers. The YZ forks are longer than the stock forks so you will have to install some sort of bar risers. I used the Powermadd risers. The front brake system I used is the YZ brake system. The master cylinder doesn't have a brake light switch connector so I found that a 2008 and up Kawasaki KLR 650 works great. You will have to route the front brake line up and over the gauges, you can still see the gauges if you run the brake hose close to the handle-bars.

Here is a detailed list of all the parts you will need for the conversion: 1) 1999 to 2003 Yamaha YZ 46mm forks. 2) 1999 to 2003 Yamaha brake caliper with hose. 3) Yamaha YZ front wheel with brake disc and axle with 2 spacers. 4) One extra wheel spacer(cut down to a 1/2" inch. 5) Kawasaki KLR 650 master cylinder 2008-2015. 6) Cable guide (I had a box of dirtbike parts and found one that worked. 7) Powermadd bar riser (7/8" to 7/8" 4 1/2" long) is what I used but if you want 1 1/8 fatbars you have that option. I attached pictures of every item.

 

[Shawn Johnson]

More pictures