XT660R/X USD conversion build
 

Album that contains most of the pictures: http://imgur.com/a/7GTFA

Ive long thought about a usd conversion, so when it started snowing i started planning!

I first bought a USD kit from a KTM 620 SUPERCOMP (wp40mm), that was a mistake, The tripple clamp was not wide enough. The only good thing was that it has a 17mm front axle, same as XT, since i recently bought a new front rim, i didnt want to buy a new one.

http://i.imgur.com/UC0BQ6I.jpg

http://i.imgur.com/jxnmzr3.jpg

I just recently purchased a KTM 640 LC4 Tripple clamp, since its using clamp sizes 57 and 54, its possible to use the older WP48mm.

http://i.imgur.com/wUi55YX.jpg

Nice work. I'm curious, have you done anything else to accomplish this mod? Like:
- Steering stem adjustments
- Wheel spacers
- steering lock
- steering stop
- fork respring revalve
- change of ride height due to: longer suspension travel or different length forks
- any difference in steering geometry

Lots of questions, I know. I hope you want to elaborate...[emoji4]


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Ive not mounted the tripple clamp yet, only test fit :)

I have the OTR raise kit in the back (3,5cm) so i hope it will work.

Ill have to weld a custom steering stop.

I dont think ill use the steering lock, instead ill use a disc brake lock.

Wheel spacers and brakes is an issue im going to deal with later! :)

I think that the XT standard tripple clamp offset is 20, so is the new clamp!

Right now im waiting for a new wider tripple clamp.

Hope i answeared all your questions!

Hello

Wondering after we spoke about your front fork. The 620 super comp -00 has the 43mm USD. The 1999 has the non USD fork so your fork probably come from a motocross as you told but wich one? Good guide and hope to see more :)

Seems to be from a 1995 (according to seller) 620 supercomp
part nr for the shocks are: K4T95L

Something like this one
http://www.motorcyclespecs.co.za/mod...c4_SC%2096.htm

New Triple clamp arrived!
 

Removed the stem from the xt and from the new clamp.
Xt stem required heat plus about 7000kgs of pressure to get moving.

Recived the KTM lc4 supermoto triple clamp, it looks a lot brighter now!

http://i.imgur.com/CwaaBUj.jpg

As you can see on the picture this clamp is much wider.

This clamp was a bit damaged, but it will be machined off.

http://i.imgur.com/0mXcKuN.jpg

http://i.imgur.com/lg28A09.jpg

I turned in the triple clamp on machining today, with this paper, FYI it is written in swedish, I will translate it if the triple clamp works on the bike!
Not 100% sure that it will fit with this modification, so dont take it for granted!

http://i.imgur.com/nrgNlCx.jpg

http://i.imgur.com/TQelJ57.jpg

http://i.imgur.com/XI6bioj.jpg

http://i.imgur.com/TToIq4t.jpg

Holy **** I just pressed out a XT stem on my lunch but not so much, around 4.5-5 tons when it starting to move.

http://images.tapatalk-cdn.com/16/01...217bfb8844.jpg

http://images.tapatalk-cdn.com/16/01...7ee0e947e6.jpg

Triple clamps from 525 SX 2006
The stem fits directly to the triple clamp but will fasten it under like I told when I spoke with you.

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The tripple clamp is on the bike!

Unfortunatly the forks didn't fit, since the bottom clamp supports 60mm forks and the forks i have is 57mm bottom mount.

I have ordered Forks and front brake from a ktm 640 sm 2004! should arrive 19-24th of feb.

Here is how the clamp looks modified.

http://i.imgur.com/FzvVVK7.jpg

http://i.imgur.com/ON7rv0N.jpg

Right now im making a design for the wheel axle. WP48 is on the bike, and also the 4piston brembo caliper.

http://i.imgur.com/gq4ZLB4.jpg

http://i.imgur.com/mBMPd39.jpg

http://i.imgur.com/9LGT0yN.jpg

http://i.imgur.com/UKkCWdR.jpg

http://i.imgur.com/XIMXkWe.jpg

http://i.imgur.com/IeVsqOp.jpg

Axle blueprint done!
 

http://i.imgur.com/WHraXqg.jpg

http://i.imgur.com/aPILcLh.jpg

I will give this to the machine shop as soon as i can!