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DT125R Forum -> FORKS -> Yamaha WR250F USD Conversion Using an Extension
Post Info TOPIC: Yamaha WR250F USD Conversion Using an Extension
Calum122


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Yamaha WR250F USD Conversion Using an Extension
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Hello,

Just got back from the engineers. I know I've told many about my plans for the Upside Down Fork conversion cause I've been asking a lot of questions. Since I decided not to grind the stem down I have instead gone the other way. I'm using the original Tapered bearings to install the Yokes. 


To do this I have machined up a part that will tightly sit inside the headstock. I have made it so the bearings and race can sit inside.


See photo's to get an idea of what I have done.

 Sketch of extension:

Diagram.jpg

DSCF1486Large.jpg

DSCF1487Large.jpg

DSCF1488Large.jpg

DSCF1488Large.jpg

DSCF1489Large.jpg

DSCF1490Large.jpg

DSCF1492Large.jpg

DSCF1493Large.jpg

DSCF1494Large.jpg

DSCF1495Large.jpg

DSCF1495Large.jpg

Getting there!

BehindForks.jpg

InfrontForks.jpg

FrontEndForksampWheels.jpg

BikeFront.jpg

BikeFron.jpg

BikeRear.jpg

DSCF1509Large.jpg

DSCF1510Large.jpg

DSCF1511Large.jpg

ApriliaBrakesonBike2_zps86f4fc30.jpg

ApriliaBrakesonBike1_zpsa60a7b6e.jpg

I've been told to use the correct reservoir as well so I'll have to get this fitted to it before I test it out!

IMG_0432_zps18719993.jpg

DSCF1578Large_zps84b2dab2.jpg



-- Edited by Calum122 on Friday 1st of February 2013 03:42:17 PM

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FunkeyMunkeyDavid


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proper job that,no fecking about. plus uses the original (strong) bearings. could even be welded on and no one would know. top notch i reckon biggrin



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Calum122


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Cheers mate. Just spent 3 hours at the lathe machining this part. Trying to get all the tolerances right. Don't want it lose and don't want it so tight that it'll never come off again! I think it's jst there. I'll finish this topic off tomorrow night when I add the forks and wheels to it.

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DT-R_bradders


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looks spot on m8 this is definatly the way to do it. what barings did u use dt or wr/yzf , also how tight wat the cup in the frame was it a good fit? if it is i can use that measurement for the ones i gotta make for mine.

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Calum122


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Added new wheels!

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DT-R_bradders


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mate tht looks the dogs bollocks cant wait to start building mine up, jus gotta save a bit more for powder coating.. : /

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DT-R_bradders


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i want that rs aswell.. lol

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Calum122


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Full arrow pipe
160cc polini kit
34mm carb
ram air filter
derestricted cdi

mate that rs is quick!

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Jay_S


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thats pretty cool mate, see what your on about now, you should get a load made and sell them, :P i could be tempted,

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Calum122


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Yeah. I was discussing it.

Few problems with that idea. It takes me about 2 1/2 hours to knock that up. To get it absolutely spot on. The lathe I was using was ancient. So because of that I'd want £30 per extension.

Second thing is that not everyone gets the same USD's which would mean you measuring everything up. Then I would make it. If you got it wrong you'd end up with a part that didn't fit and would most likely complain and that's a hassle I don't want lol.

And I don't own a lathe :/

I got some more photos to upload

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Jay_S


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£30 sounds good, i may look into doin the WR usd setup then

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Calum122


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Like I said. It's not as simple as that. They'd have to be the same year as mine or same model.

I'm sorry but it wasn't a service I'm willing to offer. If you do get the same setup as me. Use that diagram above. That's spot on.

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Jay_S


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ahh thats cool mate didnt mean for you to make me 1, just ment if its just a case of making 1 of those spacers i may look into it

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Calum122


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Yeh. It's still not that simple. If you call that simple.

You need the right yokes right forks and the right wheel


Otherwise you're going to have to make a lot of bespoke bits. I'm not bothered since I want an SM setup but didn't want to follow the traditional route. My bike is going to be custom as fook!

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Liam12


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Looking good man!! just don't like the super moto wheels!! but still looks shweet!!! mine will soon be all ready to go with my USD's!!

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Calum122


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Oh really?

You not know where those wheels are from?

I'm not keeping them that colour lol.

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Liam12


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Just don't like supermotos haha, an no where are they from? an keep them blue they actually look nice with that color : D

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Calum122


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If I keep them blue then I'll buy the blue fox d&d graphics for my bike.

They're off a 2007 Aprilia RS125. Cost me just I've £300. Spent about £600 in total to do this conversion and I'm not finished spending yet!

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Liam12


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Gdgd man! that will look nice as fook!! an bloody hell! how so much? haha


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Calum122


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Yeah NORFE reckons I got ripped off on my forks. I don't think so. Paid £210 for forks and yokes. Paid about £70 for the brakes. Then the stainless hoses.

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Liam12


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Hmm not sure on the price of forks mine came with them already on! an what made you wanna go super moto pal?


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Calum122


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Always wanted the DTX. Didn't have enough. Just thought I'd SM as I went along.

I saw the exact same pair for for like £60 less as soon as I bought my
Ones. Was gutted.

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Liam12


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Aww man! super moto is for girls ; ) haha an yeah always the case!! you buy something then you see another one for cheaper!!

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Calum122


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Yeah. I was happy to pay that for em. As long as you don't mind then it's alright.

Super moto's are wicked. I love people like 'the only way is Yamaha'. His normal wheeled DT is epic. If you have seen his build thread then you should.

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DT-R_bradders


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cant belive ur sayin supermoto is for girls! lmao gonna upset like half the forum members! lol
n cal 2hours on a lathe is long! i could machine about 150-200 in 2 hours on one of our cnc lathes, jus programe it n keep feeding it with steel bar will go all day lol like u said tho ppl buy different forks n yoke all measurments would be off, if tht wasnt the case my boss would be like " make tht **** right now we could earn alot out of it! lol



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Calum122


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Yeah. This wasnt a Cnc lathe.

Sumo's are lush. And mine and bradders Sumo's are so wicked. Just the amount of work required to get ours to this standard is rediculous

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Liam12


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DT-R_bradders wrote:

cant belive ur sayin supermoto is for girls! lmao gonna upset like half the forum members! lol
n cal 2hours on a lathe is long! i could machine about 150-200 in 2 hours on one of our cnc lathes, jus programe it n keep feeding it with steel bar will go all day lol like u said tho ppl buy different forks n yoke all measurments would be off, if tht wasnt the case my boss would be like " make tht **** right now we could earn alot out of it! lol

 Super motos can just eat me dust as I roost it up ; )



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Calum122


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LOL!

You wait until my dtre is done. With Bradley's barrel tuned and ported and full dep system no DT will be in front.

This is way away yet so for now

Yum yum :) Dust anybody?

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ToySoldier


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except me on my dt =]

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Calum122


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Except any dt200 lmao

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