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Changing your forks
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 Post subject: Changing your forks
PostPosted: Fri Apr 10, 2009 8:07 pm 

Posts: 4706
So you want to change your front end??? You want to run USD’s but not sure on what to do? Well here is a brief guide on what to do!

First of all you will need to look at your budget to see what is within it. By far the easiest thing to do is purchase a complete front end of your choice and this will probably set you back around £300 or you can buy all the parts individually but this could end up costing more or it could indeed save you a few bob, but it all depends on what suits you!

So to start off with we will get the jargon out of the way,
USD Forks = Upside down forks
RWU Forks = Right way up forks
Six posts = brake callipers that have six pistons per calliper
Four pots= Brake callipers that have four pistons per calliper

Ok so now that’s out the way you need to look for a front end that you like. There are some things to take into consideration here and you will need to do some research. The main thing you need to look for will be the fork length and how it corresponds to your standard forks so not to upset the handling. If the forks you like are shorter than your standard you will need to have a new top yoke made called a “stepped yoke” this will enable you to have the fork lower so in theory “longer”.

Try and stick with your motorcycle manufacturer, in this case Suzuki.
You will need to plan ahead for things like steering stops (we will cross this later), Speedo drive compatibility and also steering lock compatibility, you may not be able to have one!!! also if you are buying parts separately you will need to pay attention to the wheel spindle and spacers, front wheel, brakes and callipers to make sure they will all align upon final instillation. Also will the brake master cylinder be powerful enough to power the callipers?

So the main things on the shopping list will be:
1, Forks
2, Yokes (triple clamps)
3, Wheel spindle (axle) and spacers
4, Wheel
5, Discs
6, Speedo drive
7, Callipers
8, Mud guard
9, Master cylinder (front brake)
10, Head bearings (for your bike, so Suzuki Rf……)

So now we have all the parts we can crack on with the instillation.
First thing you will need to do is get your STEM (see diagram) pressed out of your bottom yoke and pressed into the new replacement bottom yoke. If your stem does not fit your new yoke dont panic. it is common, you will either need to get your stem machined down to fit or a spacer made to fit. DONT BE TEMPTED TO GRIND IT DOWN as it needs to be precise. You will also need to get it hydraulically pressed as it will take around 2 tonnes to press this out so dont hit it with a hammer as this will ruin the thread....

Now that you have changed your stem you will need to install the new head bearing. Once this is done you can now insert the bottom yoke into your bike (obviously once your old forks have been removed).Once this has been installed you will have to install the top head bearing and tighten the ring appropriately (see your manual if you are unsure of how tight). Now that the head bearings etc are installed you can put the top yoke in place and secure it with the stem nut.

Now you can install both fork legs making sure they stick out of the top yoke by the same amount as your old forks did.... for example 10mm. now this is the stage we need to check the steering stops. To check the steering stops, turn the bars in both directions until they stop and make sure the fork legs DON’T touch the frame. If they do you will need to take the bottom yoke off again and correct this by making/re-locating the steering stops.

once this is done you can go ahead and install the wheel the way you would normally and then install the callipers. Drop the bike down and make sure all is as it should be then proceed onto bleeding the brakes etc. now you can stand back, take a deep breath and admire your work!!! ....WELL DONE TO YOU!..........

Disclaimer
I take no responsibility for any errors that may occur, this is a guide only. It is always best to have a helping hand and do not attempt if you are un-sure about anything or if you do not feel confident enough!



This is a diagram showing the a normal set-up:
Image

This is a diagram showing a "stepped yoke" for use with shorter forks:
Image


Last edited by suzukib on Sat Apr 11, 2009 3:03 am, edited 1 time in total.

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Changing your forks
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 Post subject: Re: Changing your forks
PostPosted: Fri Apr 10, 2009 8:45 pm 
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Joined: Wed Mar 04, 2009 3:40 pm
Posts: 40
Location: Staithes Yorkshire
And you should end up looking something like this.

hayabusa forks


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Changing your forks
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 Post subject: Re: Changing your forks
PostPosted: Sat Apr 11, 2009 7:23 pm 
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Joined: Sat Mar 14, 2009 8:16 pm
Posts: 63
Location: leeds
nice one
theres somebody fightering a rf900 on the dtp forum
interested to see how it turns out


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Changing your forks
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 Post subject: Re: Changing your forks
PostPosted: Wed Apr 15, 2009 9:04 am 
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Joined: Tue Apr 07, 2009 7:12 pm
Posts: 39
Location: Youngstown, Ohio, US
:goodpost: Great post! It took a bit of the mystery to it all away. Thanks a million!


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Changing your forks
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 Post subject: Re: Changing your forks
PostPosted: Sat Apr 18, 2009 10:57 am 

Posts: 4706
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no probs mate, hope it helps :D


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