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KLX650 fork swap to XT660, with pics. easy job!
Ive decided on the klx650 forks for this project for several reasons. The main being: cost, availability and ease of fitting.
They cost me $250 with the axle and triple clamps. These are not as sought after as the wr or cr forks so can be easily found. the wreckers I found had 5 sets in stock, so they arent a big seller. (I ended up buying 2 sets, so I have an extra pair for future projects etc). The upper and lower bearings bolted straight in, so no bearing swapping. the stem was almost the correct length, a little shaving of the reataining nut will get around this. some mods to consider will be this: 1: the xtx axle was thicker so one fork leg will need to be drilled and tapped so the axle screws into it correctly. 2: I'll have to make up a plate to fit the black 4pot brembo caliper to the fork leg, no big problem as it kind-of lines up ok. (will post pics later). 3: a tang will need to be welded to the frame for the steering stops. 4: I'll make up a plate for the steering lock/ignition (hopefully lock will still work ok). I'm sure the KLX forks will be more suited to the weight of the XTX so hope she will handle ok with these forks. I'll add more pics of the project as I go. any comments welcome! http://i281.photobucket.com/albums/k...pse613ef01.jpg http://i281.photobucket.com/albums/k...psd7da284f.jpg http://i281.photobucket.com/albums/k...ps60e3eef6.jpg |
Really nice how about the steering stop?
Skickat fr�n min GT-I9100 via Tapatalk 2 |
sorry for the late reply.
Im just doing the job at the moment. I made up a 5mm thick alloy plate for the ignition lock and a plate for the disc mount. everythings going well with hardly any mods. bearings etc fitted perfectly. the kawasaki forks are about 3" longer, so I've sat them higher through the clamps. I will have to weld a small piece of solid steel for a steering stop that will be at the front of the lower bearing holder. I shaved about 3mm off the ignition lock bracket thats welded to the frame so as to clear the ignition lock bracket I made. steering lock still works fine. I had to belt the bracket I shaved down a little bit as the handle bar mount nuts were rubbing on it. I have 2 XTX's so will compare the handling over stock suspension soon as shes back on the road. will post pics in the next couple of days of the completed project... |
XT660 with KLX650 fork swap
heres some pics:
I still have to belt the bracket in a bit more as the steering lock tag is still rubbing on the handle bar mount nuts... http://i1295.photobucket.com/albums/...ps686d269f.jpg the bars are a little bit higher due to the risers/bars so the clutch cable is a bit short. http://i1295.photobucket.com/albums/...pse7488c51.jpg the caliper mount was easily made and fitted well. It's only a template at the moment so I'll make a thicker one after I get the rim fitted to the hub. http://i1295.photobucket.com/albums/...ps3828871c.jpg http://i1295.photobucket.com/albums/...psd24032ae.jpg The steering stopper will have to be welded roughly where the masking take is here: http://i1295.photobucket.com/albums/...ps6600cfd1.jpg I forgot to mention 2 holes needed to be drilled for the allan bolts on the lower clamp so the headlight bracket could slip over them. Also the axle hole on the KLX is smaller than the XTX axle (only the threaded end). I had to have the fork (caliper mount side) re-threaded to fit the xt axle. the width was the same and the other fork side was the same so no real problem there... Ill upload more pics as I go. |
Blimey looks good!!! How much thicker are these forks compared to the standard XTX??
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hi Simon, mate the forks are the same diameter as the XTX (43mm). I really dont think these will be any better than the standard forks on road as a motard but maybe ok for more bumpy riding on the dirt. This swap may be better for the XTR rather than the XTX... in my opinion.
it's all I had to work with at the time and at $250 were cheaper than buying new fork tubes to replace the bent ones I had on the original forks... |
finally finished, well nearly! just need to fit the single akra and make up some header pipes... this wont be for another month as I'll be overseas till then. will keep you guys updated on the actual handling. all up the front end is 1.5" higher with the forks dropped down the way I have them (1.5" above the top triple clamp). All up the only machining I had to get done (apart from making up the 2 alloy plates), was getting the fork leg drilled and threaded to fit the xt axle...
hope this info helps anyone else looking into doing a fork swap... the end product: http://i1295.photobucket.com/albums/...ps92f883fd.jpg http://i1295.photobucket.com/albums/...ps788aeecf.jpg http://i1295.photobucket.com/albums/...psa7089a6e.jpg |
Cracking job Hypoboang and good write up too! :smilies0942:
*types this while checking UK eBay for KLX forks* B*gger - none in the UK. Clearly another bike not sold here or sold in very low volume :sad9: |
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just need a top bearing & the XT bottom bearing.... steering stops are easy to set up.. The XT's look good with a set of USD's..nice job....:thumbsup[1]: |
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Thanks for the response, and wow they sure look good mate!!!!
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Great job mate.
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of 05 YZF250 USD's & clamps... they use the same bearings as the XT... keep looking... something is bound to turn up... |
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Do you still have the YZ forks? Why didn't you use the YZ forks instead of the CR forks? Are the YZ fork bearings the same as the XT's on top an bottom? Do you want to sell the YZ forks? Robo |
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Why CR forks..didn't have the YZ at the time... CR forks are gold... Bling Bling Bling :rofl[1]: I have to correct ... they have the same bearing as the TTR250 don't know why I said XT... as the TTR is what I bought them for.. bearing in most cases are not a issue... Top bearing will be the one thats diffrent... you will most lightly need a 28/52 which they make.. XT has a 25/52 top & 30/55 bottom.. But anyway I will measure them up & tell yer for sure if it will be a drop in fit & what bearings will be required.. |
I,am going to buy a TT600RE this weekend and also going to buy a set of KLX650 fork incl wheel and brake. We will see how the bearings will fit on TT660RE. What kind of fork protection did you fit your KLX650 forks, the stock ones are expensive!
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This interests me as I have a motarded KLX650R in the garage that the XTX is replacing (stupid kick starts), wondering if I should pull a sneaky and swap out the forks before selling the KLX as that looks super hot!!!
Landton - fork protection for the KLX is relatively inexpensive if you go generic |
Hello
If I buy them here in sweden they cost about 60 euro compared to KTM cost the half of that price. :/ My forks are from a KLX650 C and don,t have any adjustments like the R are I,am right? How do you paint your yokes black on you KLX? :) Skickat fr�n min GT-I9295 via Tapatalk 2 |
heres another fork swap I recently did to another xtx. (with new xtr plastics). I didnt have any original fork protectors so just used the stock xtx ones but had to add the rear section of a local 2 piece motard front guard...
I took the bike on a good run with my wife and a fully loaded 45L givi topbox. All went well with excellent handling especially at higher speeds. The forks actually added about 1.5" to the front end height from memory. In hindsight I should have brought the rear up a little to compensate as the side stand (or something down there!) was scraping when hooking into left handers. http://i281.photobucket.com/albums/k...psbce72237.jpg http://i281.photobucket.com/albums/k...ps26db0cb6.jpg |
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Sorry for digging up an old thread but I cannot find information else where... May I ask how did you remove the ignition lock? I'm having problem with removing it out of the top clamp :( Thanks, Dan |
You have to grind a line on the screws and use a screwdriver, it worked for me. Some People just drill them off.
Skickat fr�n min F5321 via Tapatalk |
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Btw, are you from Sweden? :D |
Don, t know about the KLX stem, I have only used KTM triple clamps and the XT660 stem fits very good in the bottom KTM triple clamp.
That.,s correct :) Skickat fr�n min F5321 via Tapatalk |
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https://scontent.fsgn2-2.fna.fbcdn.n...08&oe=59981821 https://scontent.fsgn2-2.fna.fbcdn.n...a3&oe=5977A167 https://scontent.fsgn2-2.fna.fbcdn.n...ce&oe=598081D0 |
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