Front End Forks Swap YZ

[WayneC]

It seems Husky traditionally used the same bearings as KTM/Husaberg which is a 29x50.2x14mm bearing so it looks like the 29x48x17.5mm is incorrect

 

[Rickyme]

It seems Husky traditionally used the same bearings as KTM/Husaberg which is a 29x50.2x14mm bearing so it looks like the 29x48x17.5mm is incorrect

Thats a bit of a bugger, thanks though

 

[WayneC]

Yes the bearing size quoted here does not seem correct, it needs some more research

I had someone cross check the OEM upper fork dimensions and I was incorrect in the dimension for the lower yoke I posted earlier in the thread, it is actually 58mm so the WP 4357 WP wont bolt in as per the BM G650X/F800GS/HP2. The BM owners mentioned some of the high end Marzochi 45mm Shivers had a 58mm lower dimension so they would be an option for the Terra (most 45 Shivers are 57mm)

The other aspect is length, I am told the Terra measures 870mm centre of axle to top of fork, this means the Terra is 65mm shorter than the YZ

 

[Rickyme]

im not allowed to PM you for some reason Shawn

 

[Rickyme]

Looks like im going it alone
YZ Front end has arrived and the fork tubes slide in with minimal persuasion, my terra disc is bent to hell so Im not going to miss that too much I reckon the terra front wheel is probably cheese so if im going to use the suspension as I plan the YZ wheel being Takasako will be up to more abuse
2 Options for springs at the moment, progressive or what is deemed more modern non progressive
Im going to get a new shock a little later which will have a bit more travel and adjustably so probably shorten just 3 cm
going to see some local guys tomorrow.

 

[mag00]

I don't understand what you mean by "concerns of the originator" ???
I AM THE ORIGINATOR OF THIS/MY FORK CONVERSION. I didn't go to any other blog/threads/posts.
One day I thought "hey" I wonder if I can put a dirt-bike front end on my Terra since I was sick of how bad the stock for was. I measured the original forks and found the Yamaha YZ front end would fit. Then AFTER a year I found this site and I posted this thread.
By the way (WanyneC) I see you don't even own a Husqvarna motorcycle. WHAT THE #%& ARE YOU EVEN ON THIS SITE!!! I suggest you don't post here until you are part of OUR site.

Hi Shawn, thanks for the writeup on the swap.

Wayne has been instrumental in our getting the GS911 to work on the Terra. He has been party to much of the BMW info for the 650 singles and has been doing this for quite some time. Our bikes run a platform of the BMW 650 single.

I believe Wayne is just pointing out that the brakes you used have proven to be inadequate for our heavy bikes. Also, the Yz front swap is not new, especially for the BMW owners, the sister bike to ours.

It may very well have been I who got Wayne interested in the Husky because our ecu's are quite similar. The Sertao, from which we can rob many parts, has problems as well, and I try to help where I can, and any similar technologies helps US, the Terra owners. Also a couple/few Terra Nuda owners live in the same area as Wayne, and he has hooked their bikes up and done R&D for our Husky Community.

I don't see anybody else stepping up to the plate in the same manner as Wayne, and he doesn't get paid to do it or sell a product either. And yes, he is pretty much an expert, and yes, he documents this well, which helps us all, now, and in the future.

http://forums.bmwmoa.org/showthread.php?28793-Catastrophic-Forks-Failure.
http://www.f650gs.crossroadz.com.au/FFIntro.html

Wayne has investigated this, and wishes to help us prevent something like this happening.

You may get away with the weaker brakes. It may be just fine for most, but understand the physics and engineering for a heavy bike like the TR or BMW vs a Yz, have different needs.

I do appreciate your work on the bike, and the info on the swap. We all contribute our findings as we go along for the rest who want better forks. Keeping it in one thread makes things easier to find. This is not put down on your great work, but rather building upon your work for future refinements. Thanks for posting it up.

 

[Rickyme]

Forks have gone to suspension shop who reckon the,yll be fine in the triples and yeah shouldnt have have any trouble with a motox brake. prob going to shorten to around 250mm travel as that will take up the available space under the guard
Ive been fortunate to find a young suspension gun who loves this kind of work
I reckon I should confirm that is after sag, i will be adding a complete new adjustable shock which I want to get another couple of inches of travel out of.
The wheel I got has a few irregularities...tossing up whether to get a new black excel and powder coat the hub red before I install the forx ..this bike is my daily run around
When I do rear shock maybe do the back wheel same.
I really hope the motor last on this thing !!

 

[Baddrapp]

Hi Shawn, thanks for the work. One question. Is the yz fork 1mm bigger on the lower tripple then our forks?

 

[Shawn Johnson]

Hi Shawn, thanks for the work. One question. Is the yz fork 1mm bigger on the lower tripple then our forks?

Yes that right. I shown in a earlier post you will have to spread open the stock triple clamps with a screwdriver to install the YZ forks.

 

[mag00]

I Like I said before. I didn't go to or use any threads/blogs/post to do my research before I did MY front end fork conversion. I didn't know this has been done before. As for other peoples input I guess I will have to take it "with a grain of salt" I don't mind constructive criticism but when you don't even own the bike we are posting about, I feel you have no right to post here because you don't know, or have the "personal experience" of owning and riding the bike. I also understand this site is for everyone to use but they should change the policy and have ONLY people the OWN Husqvarna motorcycles post here. I don't feel the GS650 is a sister bike. I only has VERY few parts that are interchangeable, it's more like a long lost 3rd cousin than a sister bike. That's the whole point of having a "Husqvarna Community" not a "BMW" community.

The BMW 650 single has way more parts in common with the TR650 than all the other Huskies combined. Sorry, you can't be a Husky purest on this bike. That's why we get a "Special" section at the Cafe

 

[Rickyme]

Shawn youre back !! good stuff

Im not alone in against the nay sayers

The suspension guys I found said some thing like " mate it"ll be fine it wont break and the YZ brake is strong enough... its your bike so do what you want with it "

GS650 not a sister bike... its a sissy bike, its designed for your girlfriend when a man has got too old to ride dirtbikes and buys a GS1200.
Yes I have ridden one and it was just horrible compared to the terra , I wouldnt bother trying to make it better - probably just sell it and buy a KTM 690
I also reckon GS1200 s are kindve un adventure bikes they are just too bloody big I mean how adventurous can you be if you cant pick it up if it falls over on a bit of a slope or mud.

Baddrap - yes its just that little amount bigger, you can get it in easily if you have someone to jam a screwdriver in the clamp while you slide it up through the tubes.

 

[Rickyme]

The BMW 650 single has way more parts in common with the TR650 than all the other Huskies combined. Sorry, you can't be a Husky purest on this bike. That's why we get a "Special" section at the Cafe

UM yeah lotta parts in an engine

 

[Shawn Johnson]

When you are about to install the front wheel there is a procedure you must follow so everything rolls freely. First you mock up the wheel onto the forks(don't forget the extra 3/8" inch spacer). First you tighten is the left pinch bolts. Make sure the axle is all the way too the left. Then you take the bike off the stand and compress the forks a couple time to align the front end. Then tighten the nut(the axle is a bit short but you still have plenty of threads to get the nut tight) Then tighten the right side pinch bolts and your done.

 

[Baddrapp]

I gotta do something. I'm an old slow guy, but dang these stock fork hit hard when they bottom out. Happened too many times in Moab.

 

[Shawn Johnson]

I am very happy with MY fork conversion. I have already posted all the necessary parts needed, and instructions how I did it.

 

[mag00]

I can understand the disdain for BMW, they kicked us to the curb. That doesn't change the facts about who made our bikes and how much of it is BMW 650 single.

 

[Rickyme]

Just mouthing off really

Normally no one takes any notice

 

[mag00]

I like your sarcasm.

LOL, I was wondering how you address bottoming out of the tire and fender or if that is even an issue (or did i miss it in the post). I have my stock tubes slipped up in the yokes, and fear one day it will bottom and send me over the bars. When I spoke to my local fork guy, he was talking about using the 426 forks and putting spacers in the tubes and different springs, and even mentioned better cartridges than the yami ones. My eyes just glazed over to a point, as the dollar sign kept spinning like I was at a casino slot machine.

We also discussed modifying the stock fork tubes to accept some decent cartridges. Alas, I do not have a spare set of forks, nor wish to spend big bucks on a set, especially when I can get a whole yami for $400.

How much clearance do you have from the tire to fender? Will the forks compress past that?

 

[Rickyme]

LOL, I was wondering how you address bottoming out of the tire and fender or if that is even an issue (or did i miss it in the post). I have my stock tubes slipped up in the yokes, and fear one day it will bottom and send me over the bars. When I spoke to my local fork guy, he was talking about using the 426 forks and putting spacers in the tubes and different springs, and even mentioned better cartridges than the yami ones. My eyes just glazed over to a point, as the dollar sign kept spinning like I was at a casino slot machine.

We also discussed modifying the stock fork tubes to accept some decent cartridges. Alas, I do not have a spare set of forks, nor wish to spend big bucks on a set, especially when I can get a whole yami for $400.

How much clearance do you have from the tire to fender? Will the forks compress past that?[/quo


Yeah so you should really address that hitting the tyre issue I think, My forks are being reduced to 250mm and of course you need new springs, I probably will bottom out these new forks from time to time as I want to ride it a lot harder than I can now.
A lot of suspension guys talk about open chamber forks as if they are no good, they talk about cavitaton and all sorts of horrors and wonderful fixes.I don t really think its that relevant for our 170 kg terra it will never be a dirt bike
The next gen YZ fork which is 48mm is a closed chamber and considered much better ...for motoX, they take more set up and demand more maintenance. and of course they wont fit in the terra triples.
All this stuff Shawn would have researched before he found the 46mm Kayaba which he has detailed the expenses for. Its a lot more expensive to do anything to bikes in Aus so consider yourself lucky if you live in the US - mind you our engines seem to run a lot better over here
My fork set up is costing twice what I paid for the forks so yeah has to be factored in also I dont want to run risers as I really like the terra ergos
I have open chamber KYB forks on my 2013 WR300, I normally ride snotty single trail not motox and they are awesum, if the terra front can be half as good as that its money well spent.

 

[Shawn Johnson]

Of the 2500 + miles I have rode the bike I have bottomed the front fork less ten times ,and each time I just herd the typical tire to fender "crunch" sound. Never did the bike get out of line, jerk or slow me down. I have never had no damage to the fender from it.
I just got back today from a 200 mikes ride and I lofted the front end a few times without bottoming the front end.
I am an ex off-road racer from a long time ago, but I still have the need for speed and I'm not your typical "Squid or Poser" rider. I ride fast and hard(for the most part), but I definitely know the limits of the Terra. I ride 90% fast fire road, 8% double track and 2% single track.
I have .48kg forks springs installed, 10w oil and the oil level one inch higher than stock.