| Author |
 Topic  |
|
|
PDXthumper
Portland, OR
USA
42 Posts |
Topic started on 12/22/2008 at 12:39:44 AM
|
I am in the middle of a 2001 CR500 USD conversion to a 2000 xr650L.
Here is what I know so far:
There are several good post about USD conversions around but most deal with the Showa 47 forks from aluminum frame bikes, see rock seven heaven for a comparison.
The CR500 from 1996 or 97 to 2001 used KYB 46mm USD forks. With these forks you do not need to use the Eming stem bushing because the upper triple from the CR and XRL have the same diameter hole. Now the lower stem bearing on the CR is larger than the XR, and the upper clamp is 6mm thicker than the XR, so bushing the XR stem to use with the CR lower will not give you enough thread engagement on the upper nut. You have 3 options to adapt the stem for most CR/f/x conversions: 1. Emig stem ($150), 2.Two wheel racing bearing ($45), 3. Turn down the CR Stem, I know people do this but it really doesn't leave much wall thickness on the stem. ($?). I chose option 4 make my own, but it cost me $20 in material and 4 hours of time, I had free access to a lathe.
Issues with USD conversions:
1. The steering stops from the CR's do not line up with the XRs.
2. If you want the key switch you need to make a new mounting bracket
3. CR wheels use larger axles, so you loose the speedo and cluster.
Using the CR500 kyb forks/triple and TWR bearing with the CR stem is a bolt in USD conversion with no machining. You will still need to figure out how you want to handle the 3 issues with any USD conversion. You can get the Forks, Triple, Ft wheel and new bearing for $300 bucks or less. Another $375 for seals, springs and valving, and its going to cost about $700 bucks before you sell off your old XRL parts.
I am interested in what others have done to adapt the lower triple clamp to hit the steering stops on the 650L frame.
Thanks.
|
00 XR650L - XR650R carb & throttle, XR600R CDI & stator, battery relocated, XR400R oil cooler, Suppertrapp IDS2 exhaust, Clarke 4.7 gal tank, UNI Filter, CR500 USD forks, Protaper bars w/Trail Tech & GPS, Moose skid plate, flush mount signals, enduro taillight, IMS pro pegs, side cover pin mod (front, back) |
|
|
flatfender
Belle Fourche, SD
USA
245 Posts |
Posted on 12/22/2008 at 02:03:29 AM
|
I am in the research process, I have yet to buy anything. My goal is to do this easy, with the least amount of running around, I want everything to arrive and just bolt it up. I have read that 2002-2007 CR forks have the steering stops in the correct location. I have seen pictures of the lower triple clamp and it looks to me to be okay, as far as the stops go. If I buy the Emig stem and upper bearing bushing there should be no machining. It seems that connecting the forks to the frame is the easy part. Using the stock speedo is still in question, truthfully, I'm loosing my patients trying to get info from people that write like "i did this u can 2, it ws e-z".
I know one thing, if I'm going to do this I want the dual chamber version, 2002-2007 CR forks, I think the CRF250/450 forks are the same but not sure. The last thing I need to know before I do any purchasing is how to use the either the stock speedometer or a vintage analog type. No way I'm using an LED speedometer, it's a generational thing, much like a preference to dial wrist watches.
It may be possible to machine a split bushing for the fork end clamps and use the stock 650L wheel/axle and speedo drive. No one has posted any info on that yet. I may have to get the CR forks I want and use the CRF450X wheel and speedo/odo drive and what else? Which brake caliper would I use? I know I'm totally missing something, maybe I should look for a complete CRF450X front end? I have to find out if the CRF450X has the steering stops in the correct location now.
As far as your question I think most have machined off the CR steering stops and welded aluminum blocks in the correct location for the XR650L. |
98 XR650L - FCR-MX, Thumper Racing baffle, IMS 17 liter tank, XR250 oil cooler, etc. |
|
|
flatfender
Belle Fourche, SD
USA
245 Posts |
Posted on 12/22/2008 at 02:07:18 AM
|
| Where do I go to see rock seven heaven for a comparison? |
98 XR650L - FCR-MX, Thumper Racing baffle, IMS 17 liter tank, XR250 oil cooler, etc. |
|
|
Admin
4Strokes.com
USA
7798 Posts |
|
|
PDXthumper
Portland, OR
USA
42 Posts |
Posted on 12/22/2008 at 11:18:14 AM
|
My XRL brake caliper bolted up to the CR500 fork, however the rotor is ~1/2 inch smaller, I haven't mounted the wheel to verify the fit up.
You can modify the CR axle you use the XR wheel and speedometer. I don't think you need the Emig stem if you use the two wheel racing bearing (lower), it is suppose to fit the XR race diameter, CR stem diameter. Depending on the stem diameter and upper triple stem bore you may need the emig bushing and a second TWR bearing there as well.
The CR 500 upper clamp for KYB may also work for the Showa 47, I believe the upper fork diameters are the same.
The easiest way to do this is to use the whole front end of the donor bike: forks, wheel, triple, axle. |
00 XR650L - XR650R carb & throttle, XR600R CDI & stator, battery relocated, XR400R oil cooler, Suppertrapp IDS2 exhaust, Clarke 4.7 gal tank, UNI Filter, CR500 USD forks, Protaper bars w/Trail Tech & GPS, Moose skid plate, flush mount signals, enduro taillight, IMS pro pegs, side cover pin mod (front, back) |
|
|
flatfender
Belle Fourche, SD
USA
245 Posts |
Posted on 12/22/2008 at 2:04:09 PM
|
I just thumbed through that website admin linked…that is the info I have spent hours trying to find. I will look more after work. I like his idea about the steering stop mod.
 |
98 XR650L - FCR-MX, Thumper Racing baffle, IMS 17 liter tank, XR250 oil cooler, etc. |
|
|
oregonlmd
XR650L
USA
2 Posts |
Posted on 01/05/2009 at 10:02:31 PM
|
I acquired an XR650L in December, and have been looking at the set of forks from a 2001 YZ426F that I have as a likely swap onto the XRL. I figure they're the same forks you're talking about using from the CR500. I think the YZ/WR426 (and 400) lower clamps may be a good solution to the steering stop problem, as they have the same steering stop setup as the XRL uses. Further, it appears that the clamp and axle offset is pretty close to what the XRL uses. I have yet to take the XRL forks & clamps off my bike to verify measurements, but they do appear to be close. Also, it appears that the XRL steering stem is smaller enough in diameter that the required shims to fit the XRL steering stem into the YZ/WR clamps would have enough meat to be easily machinable, thereby making it easy to continue use of the XRL steering bearings.
So, am I way off in left field on this, or what? What more do I need to take into account on this? Since I've already got these forks (and the front wheel), they're what I'm going forward with unless there's something obviously wrong or difficult about this swap that I've not yet taken into consideration.
I welcome any input on my idea. |
|
|
oregonlmd
XR650L
USA
2 Posts |
Posted on 01/06/2009 at 12:39:08 AM
|
More info on the YZ/WR426 forks:
I just disassembled the front end of my XRL and did some measuring. Here's what I found:
XRL bottom clamp steerer ID = 28mm. Upper clamp ID = ~24.5mm.
YZ/WR bottom clamp steerer ID = 32mm. Upper clamp ID = 25mm.
The lower shim to press into the lower clamps would have a 2mm wall thickness. The upper would be very thin. I'd be inclined to use a feeler guage of the proper thickness for a shim there (about .010" by my estimated calculations).
Bearings are completely different, so re-using the XRL bearings would be necessary.
XRL headtube length = 7 1/4"
YZ/WR headtube length = 7 3/4"
The YZ/WR steerer is longer than the XRL by about the same 1/2" that the YZ/WR headtube is also longer, but the upper clamp design seems to just about negate this extra length as a problem for the swap. I think that the upper bearing will end up sitting where it needs to on the XRL steerer after it has been installed into the YZ/WR lower clamp.
XRL axle center to bottom of headtube distance = 28"
YZ/WR axle center to bottom of headtube distance = 27 1/2"
Both measurements are with the forks at full extension. I assume this difference would not be a real issue.
Finally, the offset is the same, and I measure it to be right at 25mm.
The YZ/WR clamps have the bars offset slightly forward of the steerer centerline, a big plus for me. The XR/XRL bars are too close for me.
As far as using the stock switch as a locking device, that's something that somebody else would have to deal with on this swap, as I am not concerned about it.
It appears that this swap is very doable, and I will be working toward completing it by spring. Again, any input is very much appreciated.
Finally, PDXthumper, I have posted all this info for two reasons. One is to give you a possible solution to your lower clamp steering stop issue, and the other is to invite input on my plans.
Also, since you live in Portland and I live in Corvallis, maybe we'll actually run into each other some day. |
|
|
PDXthumper
Portland, OR
USA
42 Posts |
Posted on 01/06/2009 at 10:46:06 AM
|
| Oregonlmd: Your swap seems very do-able. having a bushing made to fit the XRL stem to the YZ lower clamp will work well, and allow you to use the stock bearings. Your very close on the upper dia, you might want to drill or ream out the upper clamp ID, and bush that as well, might be able to use the emig stem bushing, and have someone drill your clamp to work with it. The only thing you didn't mention was the upper clamp thickness at the stem bearing. Sometimes the XRL stem is too short to use. For my steering stops I have tapped a hole in the top of the stock CR500 stops and added a "L" shaped block with short leg of the "L" acting as the new stop. the stock stops on the 500 are larger so I had lots of room to work with. |
00 XR650L - XR650R carb & throttle, XR600R CDI & stator, battery relocated, XR400R oil cooler, Suppertrapp IDS2 exhaust, Clarke 4.7 gal tank, UNI Filter, CR500 USD forks, Protaper bars w/Trail Tech & GPS, Moose skid plate, flush mount signals, enduro taillight, IMS pro pegs, side cover pin mod (front, back) |
|
|
vade
West Bend, WI
USA
2 Posts |
Posted on 02/17/2009 at 3:42:29 PM
|
PDX,
I am doing the same swap that you have done and am thinking about trying the bearing swap. Where can I find the bearings I need, do you happen to have the size or number that I would need to get them from a distributor. Thanks
Vade |
95 XR650L |
|
|
PDXthumper
Portland, OR
USA
42 Posts |
Posted on 02/17/2009 at 4:21:55 PM
|
Vade, here is the guy I ordered it from:
Zoran Vujasinovic
Twin Works Factory
775-786-4881
(Removed commercial link. -Admin)
I only need one for the lower, the upper dia were the same. I also made a plate from 1/2 in AL to mount the key switch, headlight support bracket, and a ram GPS mount that bolts through the handbar mounting hardware. If you have access to tools to make one I can send you a full scale drawing of the bracket.
Let me know if you have any other questions.
|
00 XR650L - XR650R carb & throttle, XR600R CDI & stator, battery relocated, XR400R oil cooler, Suppertrapp IDS2 exhaust, Clarke 4.7 gal tank, UNI Filter, CR500 USD forks, Protaper bars w/Trail Tech & GPS, Moose skid plate, flush mount signals, enduro taillight, IMS pro pegs, side cover pin mod (front, back) |
|
|
PDXthumper
Portland, OR
USA
42 Posts |
Posted on 02/23/2009 at 10:55:22 PM
|
| Ok I have had a chance to get around 100 miles on the new forks, 50 highway, 50 centeral oregon single track. The USD forks absoultly took care of the wandering font end, the bike went were you aimed, regardless of ruts, rocks, logs, etc. On high speed(45mph) whooped out double track the bike was nice and steady, no issues at all. So far no complaints about this conversion! |
00 XR650L - XR650R carb & throttle, XR600R CDI & stator, battery relocated, XR400R oil cooler, Suppertrapp IDS2 exhaust, Clarke 4.7 gal tank, UNI Filter, CR500 USD forks, Protaper bars w/Trail Tech & GPS, Moose skid plate, flush mount signals, enduro taillight, IMS pro pegs, side cover pin mod (front, back) |
|
| |
Topic |
|
|
|
CR500R USD fork conversion on '00 XR650L
