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More WP48 conversion
Part 1 of WP48 conversion finished today. I just had a short visit at the shop. These are low quality shots with mobile.
http://picasaweb.google.com/flatboarder/Tenere New Excel Talon wheels (red/black) will be made in Feb. Upper fork crown is tailormade from CNC'd Aluminium and will be anodized red. It locates WP48 fork (89cm of length) 3cm downward compared to stock fork (90cm of lengt) but allows relocating it upward in case. 25cm of travel compared to 21cm stock. Serious damping. Hope we can keep that 25cm when testing full travel without hitting radiator by removing fork springs. Lower crown is from stock KTM 690er Enduro. Works unchanged, but will slightly modify limiter bolts. There is no big change at riding geometry. We are trying to keep everything near to stock level. Will at max gain 2cm of height as soon as 18" rear wheel is used, but no more than that. Hopefully less. Suspension feels completely different compared to stock. Thanks to JMo for her inspiring articles and work. This will not at all be a copy. We will do it quite differently instead, but she proved feasibility of such a conversion and as soon as I saw hers, I decided to start my own project (which has been in my mind since I bought the Tenere). |
Those orange days are numbered...
Top work fella!
The more of these bikes we see converted, hopefully the more we will see racing too! Can't wait to see it finished! Jen xx |
brilliant.. really looking forward to the finished product..awesome..
now im seriously considering the conversion..:BaseballHat_LNY2EG: |
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Some more details: The upper for crown has been designed specifically for my motorcycle and the 690er WP48 fork. This means, it has been quite expensive (not at all cheaper than OTR complete set which is also very nice and black already). It fits the steering lock (front wheel heading straight when locked). The manufacturer (a major Austrian WP distributor) might be happy to produce some more of it a bit cheaper, since they now have got the CNC machine data feed. Do not know. Also the new crown utilizes KTM handlbar mounts bolted into the fork crown, no longer needing a big bolt with some big hexnut below fork cron where it is a pain. So, easy handle bar clamp change and usage of stock KTM handlebar parts, even they provided two mounting positions as can be seen in pictures. Lower fork crown needs a new shaft fitting the Tenere steering head. They also manufactured it and pressed it into lower crown. Fork mount, axle, wheel parts are fully KTM compliant. Hopefully (yet to be tested) we can even use KTM 690 stock fork setup without change of travel. This would be perfect. In fact, stock suspension setup appears to work quite will, but I have not yet ridden it. These things will happen in February earliest. I was extremely lucky buying the KTM fork in perfect condition with axle, crowns and everything for a ridiculous price. Otherwise it would have been too expensive. Actually, I have previously been riding KTM for several years and I used to like it, apart from some engine damage. I am very impressed about the new 690s that I have not yet ridden but would like to. Nevertheless, I also like the Tenere and my WR, so to me its just a matter of coexistence :) Kind regards, Phil |
Nice to see another conversion. Forks are on my list, but I've been looking at WR items. A while off yet though...
Looks very nicely done flatboarder. |
Cooool
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Looks like a seriously mean conversion flatboarder. I like it - how long before someone comes up with an off the shelf kit I wonder?:YellowWow_KKPB92:
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OTR have now CNC'd the correct top clamp to replace the Tenere one, including the holes for the steering lock etc. and you can use the original bar risers (or others) as required. The also supply the forks, so all you really need is a KTM EXC front wheel and a suitable mudguard - I'm sure OTR could supply those too, although you are better off getting those from a KTM dealer (or Talon) I imagine. For info, Meca'System do a bracket kit that mounts a 950 Adventure mudguard onto the single disc WP forks, which is the set-up I have... OTR kit: http://www.off-the-road.de/xt660z_te...eder.html?&L=1 Tell 'em I sent you... it probably won't get you a discount, but might help my future Dakar campaign... x Jenny xxx |
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http://iloapp.spanisch-deutsch-dolme...39_resized.jpg http://iloapp.spanisch-deutsch-dolme...42_resized.jpg http://lh4.ggpht.com/_ccnZ8O9XU-4/Sk...202009-153.JPG Nice conversion, but I think you need to revalve/respring the fork. The 690 is a lot lighter espeacially the front. |
Would like to see the bike once complete. Sounds awesome
Am doing my own conversion at the moment using a wr front end with upgraded springs. Have only had to put a spacer in the top clamp + engineer a bracket for the stops. Oversize disk & caliper bracket. I am going to do the Rydale and Hafren rallys on it, did the Hafren last year and would reccommend it to anyone with a big bike and some off road skill. Cheers |
Does anyone have prices and a list of parts (from other models) of what they have done to convert to wp ?
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http://www.vdsr.co.uk/ride-reports/hafren-09/15/ http://img.photobucket.com/albums/v6...s/PA250041.jpg |
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The 690's WP48 fork in fact feels somewhat softer than stock tenere fork, but it is known to be quite strong and there is 4cm of additional travel, after all. My fork crown was designed to locate fork 3cm downward to compensate for longer travel together with shortened total fork length (I did not want to cut fork travel by inserting some sort of stopper). When I did a short test ride (some yards only) the front did not feel any lower at all, but we will take care of this as soon as the bike will be rideable again. These will be the finalizing steps and it will take several more weeks until then. Nice pictures of yours. I really like the 690 KTMs which in my opinion belong to the best motorbikes, KTM ever built (as well as other manufacturers...) I own a WR250R together with my Tenere, both replacing just one 690 Enduro. However, the Tenere is very good for relaxed single cylinder touring (with baggage and stuff). The WR is good for offroad, and I definitely do not need that much power when riding offroad. My status: today I handed over my fork assembly to some metal works company to finalize my inacceptably ugly self made fender mounting bracket. The Meca System bracket would not fit my fender (African Queens GFK hand made), so we need to do our own. Pictures as always in my picasa online album. No further steps until now. Talon hubs take their time. Upper fork crown is currently being anodized. Regards, Phil |
Just returned from my favourite locksmith. Professional metalworkers finally made my fender mounting kit. Perfectly done.
http://picasaweb.google.com/lh/photo...eat=directlink http://picasaweb.google.com/lh/photo...eat=directlink That compares to the meca system kit. Slightly more expensive, but total custom work from stainless steel. Fender located at perfect position. Very happy with it. |
triple clamp anodized.
http://picasaweb.google.de/lh/photo/...eat=directlink http://picasaweb.google.de/lh/photo/...eat=directlink http://picasaweb.google.de/lh/photo/...eat=directlink http://picasaweb.google.de/lh/photo/...eat=directlink The fourth link does not work. Obviously there is some anti spam policy deactivating any more than three links in a post. Just see last picture of picasa album! As discussed in JMos thread there is in fact not enough clearance for my 25cm of travel. Although my fender is mounted deepest possible now it looks like it would slightly hit the radiator when fork gets compressed fully. We need to check out after everything is assembled. It looks like I could probably get no more than 23cm of travel or so, which makes me wonder since stock fork has got 21cm and my fork is located 3cm deeper to gain more clearence. Will see. Regards, Phil |
:wav:
Nice work Phil, great to see it coming along |
Well it's taking its time. Still no wheels. Some brake pump experiments:
http://picasaweb.google.at/lh/photo/...eat=directlink http://picasaweb.google.at/lh/photo/...eat=directlink The Magura 195 radial pump with 13mm piston will be combined with a magura caliper shown in this picture: http://www.powersports.magura.com/ty...5f8450e99d.jpg We need to find a way for fitting it to the WP48 fork by use of an adapter. These adapters are available, but ours needs some offset to locate caliper some millimeters to the left. Otherwise it might touch the spokes. The pump will fit my handlebar without any clearance to wind screen. This means, although maximum angle of turn has been reduced due to my custom triple clamps and I have 6 possible positions for handle bar on top of the triple clamp, I had some trial and error until it did fit, but it is not yet perfect. Will add 10mm of height to handlebar to give some more clearance. I am really hoping to get it all done soon. |
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J xx |
I would echo J'Mos thoughts, why make life hard for yourself and spares difficult to obtain... brembo bits abound all over ebay.
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Also I need to say, these brake parts look nice to me and it is a 4 piston caliper and maybe will give somewhat better braking. Lets see. Note my Tenere will not be aimed at Rallye Racing (although I would really like to get into it) but will mostly be a touring motorcycle with baggage and maybe a second person on it. In the long run there may be some old men rallyetouring or whatever, but not even close to what you are doing. I would not consider fitting such a brake system to an offroad sports bike as long as I would not use it for supermoto. For offroad usage I consider small disks with a typical offroad caliper completely sufficient (and actually used such systems for supermoto as well, but only lightweighted sports bikes) Phil |
That's fair enough - you are right the Magura radial caliper looks beautiful!
I can appreciate you might have TUV type approval issues in Austria - but I can't believe the Braking Wave/Brembo combination don't comply - although I admit I am not fully aware of the procedures there... I think it is an excellent improvement you are undertaking, and can appreciate you are not intending to race/rally with this machine - even though you certainly could with the amount you are doing to it! Can't wait to see the finished result! J xx |
I guess it would be impossible to get 'typisiert' (legalized) in Austria, but we will do so in Germany. One more motivation for this project, since I have been planning to go to Germany anyway.
Brake assembly would probably not be a big issue, but fork conversion and wheel width (won't change diameter after all!) definitely is when using custom cnc'd parts without any paperwork or numbering or whatever. We cannot afford doing any sort of crash tests, so they need to believe us/me it will work. Also there are so many difficult issues with certain clearance, steering angle, tire measurements, they actually would need to check accurately if they are paranoid. So I guess this is the deal: ------ they will get it done in a pragmatical way and I will most gladly and happily pay ------ aehem. --> Ok. :068: Sorry for this. |
Very nice looking mod, but isn't it expensive?
What is the difference between UPSD and a regular? |
From the economic standpoint such a modification is horrific. There is no way around this finding. It is a waste of money. It would probably be cheapest and easiest to run a motorcycle without any modifications until it will be sold. I am very sorry that in my life there was only 1 motorcycle that I kept unchanged. It got sold after half a year of usage, so there actually wasn't a big amount of time for doing modifications. But it was a very nice bike, definitely.
Technically there are some reasons to upgrade suspension technology for cheap standard motorcycles like the current XT series. I personally think there is more use in doing so than upgrading engine performance which will be kept stock level (I very much believe, I really do, yes). I will not even mention that I like these things that I am doing, winter is cold over here, lots of snow, there has always been a strange urge for doing long offroad distances far south, whatever... Getting old. |
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Ok, i's moving forward now. Yeah. Red Talon hubs came in yesterday. Rear Excel rim 3,00"x17" is there as well. Today I borrowed an EXC front wheel to be able to move my Tenere from the garage into the van. Friday it will be hauled to the shop. From then on we will count days. I already know, the front brake project will become more difficult than we thought. Most likely the nice magura caliper will not fit, since it is way to wide for enduro 21" wheel spoke scheme. But this will be worked on by professionals. At current I cannot tell what the result will be. Minimum solution would be JMo's stock caliper solution while I would prefer the Braking offroad caliper (2 piston system) which will fit enduro wheels and is not too expensive. Since I am willing to sell all my stock parts, it would probably be better not to use half of my stock front brake. I need to say, when listening inside carefully, I am slightly, slowly, softly starting to feel a light touch of impatience after two months of fiddling around with nasty small parts and waiting. blowup Update: final preview before new wheels are going to be made (borrowed front wheel): http://picasaweb.google.de/lh/photo/...eat=directlink http://picasaweb.google.de/lh/photo/...eat=directlink http://picasaweb.google.de/lh/photo/...eat=directlink Everything seems to fit perfectly, but fork makes strange noise when being engaged with my total weight. Need to check. That sound definitely does not originate from fender installation. |
My new wheels
:love10:
http://picasaweb.google.de/lh/photo/...eat=directlink Tenere is at wheel and brake shop (they do supermoto and MX conversions mostly) for finishing the project. They will also legalize everything, including the previous fork conversion. Final step will be the suspension fine tuning and optimal setup to be done at the previous shop, my WP suspension professionals who did the fork and triple clamp stuff. |
They fitted new front wheel with mentioned Magura radial caliper :eusa_clap:
No further information or picture at current, though. |
those forks look the dog's
suprised you didnt go with an 18 rear wheel but then i guess the Ten is not intended as your sole off road bike as you have the Wr for that.:Gangsta2_9BI664:very bling i like those talon huns and they suit the white ten a treat |
Under the impression of JMo's work, I have been struggling with that 18" issue for 2 months.
Well, the rear layout does not perfectly correspond with an 18" wheel, depending on rear tire and size. Since for me there are no severe technical reasons to go with 18", I kept things easy, finally. As opposed to the JMo conversion there is no special dedication for my resulting chassis. No need for certain racing tires or whatever. On the other hand I do not like to prolong center stand by welding upon it. I do not want to feed in a longer chain and I do not want to compromise rear swingarm material by dirt getting wrapped within nobby tire and swing arm surface into a very narrow gap. Also I do not want to have this bike unnecessarily elevated. And finally, I will put in an aftermarked rear shock and this way try to increase rear travel a bit, but on the other hand keep stock exhaust system (since I consider it quite well done). So, there is no use in further reducing tire/exhaust clearance by means of an 18" rear wheel. Apart from that, I like to get legalized tire dimensions 140/80-17 and 130/80-17 as well without consideration of manufacturer. With 140/80-18 this would definitely use up any clearance available and would probably lead to problems. As soon as it became clear an excel rim with 17'" x 3,00" is available, I decided to go with it (as opposed to 17" x 3,5" supermoto size which might have forced me to go with 18" x 2,5" to avoid running an unnecessarily wide rear rim). I believe, for my purpose this solution is best. I want this Tenere to stay allround and easy going. No problematic details or worryabouts. I think it will save me days of fiddling with nasty details. Also, there are lots of different tire tread patterns available with 17" tires as well. No need to go with deserts. No racing, so far... :004: Even in case of a decision to go with 18" rear wheel at some later point of time, this would mean a new rim and new spokes (and then, deal with the problems mentioned). Not extremely expensive and at least doable, just in case. Regards, Phil |
fair point what colour rims did you go for ?
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--> black. |
Flatboarder, great job, look forward to seeing it finished.
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Hi everyone,
I'm just wondering what's the advantage or disadvantage thereof, for replacing the rear wheel to an 18inch. I use my bike (XT660R) 50/50 and here in northern Mexico, the terrain is very rough and dry. Lots of sand, gravel and very, very sharp rocks... Thank's in advance for any comment. Salud amigos ! |
hi i guess the main reason for a 18'' rim is for competition use, michelin deserts i believe don't come in 17'' a lot of offroad race tyres are just not made in that size
and mousses are again 18'' though if you are using tyre balls that should not be a problem. |
As Stoic says, there is a wider choice of (tougher) off-road tyres, the option to run mousses (which in the terrain you describe would seem ideal), plus the benefit of extra ground clearance and rolling circumference as the wheel diameter is greater.
The only real downside (other than the cost of a new wheel) is that on the XT's, the speed reads off the gearbox, so your speedometer reading will be incorrect... J xx |
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Phil |
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The stock bike is 15/45, and I'm now running 14/50 (although 14/48 is probably closer to the original gearing with a 17 inch wheel)... hence the speedo is now completely out! J x |
Went to the bike shop to get a clutch lever and they told me $93 bucks aussie. Anyone know of any after market ones?
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Speedo displacement is one of those issues, I totally dislike with my two Yamahas. The WR250R is even worse than the Tenere. I realize up to 12% of displacement with worn down stock rear tire. The numbers displayed are useless (and even illegal! 10% of displacement is the legal limit in Germany as to my knowledge). The WR250R at least offers an adjustable odometer mode for enduro racing or whatever. In my opinion these digital instruments should be as exact as possible. There is no technical need for any displacement at all. Numbers are acurate. Even worse, for offroad usage there is considerable displacement anyway, due to rear wheel spin all the time. This would not happen at all with speed sensor at front wheel. Those devices should be adjustable (at least with dealer interaction) for any sort of modifications of motorcycles. I still cannot believe, transmission ratio and tire size is hardwired in these devices. There must be some way to adjust it. Since I am using a GPS mostly, speed display does not matter that much, but odometer should definitely be acurate. However, strange enough, odometer displacement is only about half or one third of speedometer displacement, which again puts some questions at use of speedhealer (which ratio to adjust). ---> Late update: all of these speedo issues have already been addressed right here (surprise): http://www.xt660.com/showthread.php?t=8876. Phil |
Front wheel installed
3 more low quality pictures shot by mobile phone:
new front wheel with Magura radial caliper and Spiegler disk. The adapter for caliper installation is a preliminary prototyp to determine detailled specification for final version. Rear wheel has not yet been built at this moment. http://picasaweb.google.com/lh/photo...eat=directlink http://picasaweb.google.com/lh/photo...eat=directlink http://picasaweb.google.com/lh/photo...eat=directlink |
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