hi uber, i sure you know why it's wooden, the yamaha cylinder is a16mm whereas the ktm is an 11mm unit giving it the correct leaverage. i just checked in the the garage, my exc and the nearly built rally ktm[must give it back] share the same cylinder, the number underneath is 4 10 .7676.the ktm manual part number is 503.13.001.100 .

just for you i also checked the gasser it's also an 11mm, even better, made by nissin so a more consistent action, the brembo cylinder can for some reason can be all over the place not very reassuring in a special test

very nice clamps, all the best with the conversion

bernard

I have a spare exc front wheel once you have some pennies to spend.

good to see the ten in action, good luck with the transformation

For those with nothing better to do, I've finally got round to writing up my experiences at the Hafren properly:

http://wildchild.org.uk/blog/pivot/entry.php?id=66

Oh, and here's my account of the BBRC rally training weekend the month before:

http://wildchild.org.uk/blog/pivot/entry.php?id=61


Waiting on some parts at the moment, but I'm hoping to have the front end swapped over by Christmas.

So I rode home last night (Thursday) to find a brake hose sat on the doormat, which was just about the last thing I was waiting on*. Obviously, I want to get the fork swap done as soon as possible, but I need to use the hydraulic press at work to swap the steering stem over from the OE bottom yoke to the OTR one. So if I wanted it to happen this weekend it was time for some hasty dismantling.

http://sphotos-g.ak.fbcdn.net/hphoto...53878649_n.jpg

Once I had the forks out, and before I committed myself too far, I made a bit of a rudimentary measurement of the spring rates in the two forks, with the aid of some bathroom scales, a ruler, and my beautiful assistant. :firework:

The forks that are going in are from a 2007 KTM 450SX, which is the MX variant of the bike. Obviously the donor bike is considerably lighter than the Tenere, probably by 70 or 80kg, but it's also sprung to allow landing from several metres in the air - which I don't plan on doing! So I'd hoped the spring rate would at least be in the right ball park.

Actually, it turned out that the spring rates are an uncannily close match. This means:

1) The bike will be rideable just by swapping them over, without respringing the forks.

2) Assuming that the forks I have still have the standard 0.46N/mm springs that the KTM would have originally been fitted with, there's at least a couple of steps stiffer springs easily available.

3) The stiffness of the stock forks is only really a problem because they bottom out on big hits. In normal riding soft is pretty good if it means you are actually using the full stroke of the suspension. Now the new forks have a good 3" more travel, so it may be that I actually want to keep them fairly soft, and just make use of the extra travel and some judicious adjustment of the air gap to make sure they don't hit the stops.

Anyway, point 1 is enough for now. So today I ducked out of work for half an hour to pop to the workshop and abuse company facilities for my own benefit ;). Result, one Yamaha steering stem fitted to an OTR yoke:


http://sphotos-d.ak.fbcdn.net/hphoto...18915485_n.jpg


Weekend of assembly ahead.




*Actually, I still need some caliper bolts, but I'm hoping I can pick those up from Leisure Trail in Notts in the morning.

Good stuff fella :thumbsup:

http://sphotos-h.ak.fbcdn.net/hphoto...63429248_n.jpg

Might need a longer sidestand:

http://sphotos-d.ak.fbcdn.net/hphoto...31421728_n.jpg

Apologies for the rubbish pictures. Seems I can't actually get outside in daylight much at the moment :D

looking good uber! i'm sure you can't wait to try the new setup out!

big disc and all, a 3oo? or 330?

That's actually a 270mm disc, so while it's oversize for an EXC it's still smaller than one of the original twin discs. Still got enough power to lock up the Swedish Army front, especially in the cold and wet - and the feel is really good, better than the stock setup.

(Of course it helps that it's a brand new disc, pads, and braided hose, rather than the OE ones with 29,000 miles of dirt ingrained into them)

Would be pretty easy to go to 300 or 320mm at a later date if I feel like I need it.

It's nearly there, just waiting on a fuel hose (Tip: Don't drop your fuel tank while it's still attached to the bike by the hose :(). Should be back together within the next week and then I'll get some photos of the whole bike ready to race!