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9 Sep 2013
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Quote:
Originally Posted by leonator
EPIC! nice work Ghosty!
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Thanks mate!
More parts coming in, I got axle inserts and top clamp insert. Due to really crappy weather  here at my place, I am thinking of ripping the bike apart this week.
So here are the axle inserts that drop the size down from KTM to KLE:
And here is the top clamp insert:
Now I only need to find a way to lift the bike up for the change, any ideas??:confused1:
Cheers!
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20 Sep 2013
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Hey all!
Here are a few of my progress pictures:
 
But there is a slight problem. When I have installed a Kawasaki wheel in KTM forks, it all fitted like it was made to fit. And so I thought. After measuring the distance from each fork to the centre strip on the tyre I got 1mm off-set left-right. :eek1
Here is my question to you:
Can this 1mm of off-set cause any safety or handling issues?
Here is the picture:
Thanks for your help!
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21 Sep 2013
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Don't measure to centre of tyre.
Measure to the edge of the rim on each side [rotate your wheel slowly to check the rim is not buckled first though].
Sometimes a tyre can be mounted slightly off on a rim so your measurement may not be accurate that way.
I suspect such a small off centre amount will actually affect the ride or safety concerns, but only riding will tell for sure.
There are bikes out there with bent frames/misaligned forks/tyres not seated correctly that people ride every day without ever noticing something is off.
Also, while riding, a tyre flexes all over the place due to road surface irregularities.
I truly doubt you will even notice it is off.
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22 Sep 2013
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Quote:
Originally Posted by Ockerstrom
Don't measure to centre of tyre.
Measure to the edge of the rim on each side [rotate your wheel slowly to check the rim is not buckled first though].
Sometimes a tyre can be mounted slightly off on a rim so your measurement may not be accurate that way.
I suspect such a small off centre amount will actually affect the ride or safety concerns, but only riding will tell for sure.
There are bikes out there with bent frames/misaligned forks/tyres not seated correctly that people ride every day without ever noticing something is off.
Also, while riding, a tyre flexes all over the place due to road surface irregularities.
I truly doubt you will even notice it is off.
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What he says ^^
A tyre is not an 'accurate' measuring device in any situation...and tbh i wouldn't be worrying about a 1mm discrepancy at all.
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16 Oct 2013
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First test ride is done, I am super excited at how the bike feels and handles with WP43 forks, it's completely different bike to ride. So far I am happy with the conversion. I still have to fine tune compression and rebound dampening as I don't even know if both forks are set the same. Overall I am very happy how it all turned out and how the bike feels.
More info on how it all went down and more detailed picture will be posted in the coming days. Here is one more for tonight:
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25 Feb 2014
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steerer stem dimensions
Quote:
Originally Posted by Ghosty_SLO
Hey all!
I know this thread was dead for a long time now but hopefully that will soon change.
I have been riding quite a lot so there was no time for wrenching, but I managed to do a few things. Mostly designing stuff for the conversion.
I have remade drawings of a stem that svestenik has sent me, thanks again mate, I have also made drawings for axle conversion from KTM (20mm/24mm) to KLE(15mm), inserts for top triple clamp and for handlebar mounts.
I still have to draw up wheel spacers, calliper bracket and ignition holder, but these will have to wait until I mount KTM forks on the bike.
Now I only need to do is give some of the plans to my father and some to a friend that has CNC equipment and wait for parts to be made.
Cheers! |
hi ghosty,
been looking through your thread with interest. I have a KLE500 and a set of Suzuki RMZ450 forks to retro fit to it.
I am lucky as I own a machine shop, so can make the parts necessary. TO save me time how-ever could you mail me the sizes (or the cad drawings) by PM.
any assistance would be good.
when I get mine done i'll post a thread.
bart
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25 Feb 2014
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Hey!
Sure I can send you the CAD files, but let me inform you that these parts were especially drawn up for WP4357 forks and 00-03 Applied Racing billet triple clamps. So in effect they probably won't work with your RMZ450 forks and clamps. But if you are still interested, send me your mail in PM and I will sent them to you.
Cheers!
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26 Feb 2014
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my steerer tube
hi ghosty,
thanks for the reply. I have blown up your pictures and taken all the dimensions I need from them. the RMZ forks have a steerer tube pressed (or heat shrunk) into them all ready. the diameters are bigger than those I need for the KLE bearing I.D's so I will simply turn them down to the correct sizes. have no fear, there is plenty of wall stock on the steerer tube as the inside diameter is 15mm.
In the real world, the bike / forks won't be taking the kind of hits an RMZ 450 is subjected to on the race track. I'm moving on quite quickly with mine, i'll post pictures as and when I can.
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26 Feb 2014
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I also wanted to just turn down the KTM steering tube, but my clamps came without one so I had to made it from scratch. Good luck with your project and do show some pictures here.
Cheers!
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22 Apr 2014
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Quote:
Originally Posted by 888bart
hi ghosty,
been looking through your thread with interest. I have a KLE500 and a set of Suzuki RMZ450 forks to retro fit to it.
I am lucky as I own a machine shop, so can make the parts necessary. TO save me time how-ever could you mail me the sizes (or the cad drawings) by PM.
any assistance would be good.
when I get mine done i'll post a thread.
bart
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Hi,
please check clearances between lower triple tree on RMZ450 forks and KLE 500 frame, you could loose a lot of steering circle.
I have at first mounted KTM forks on my KLE 500 and then curiosity got better of me and I mounted DRZ 400 front end on it. While KTM forks had enough clearance to achieve full steering lock, DRZ 400 lower triple hit the frame and left me with less than half of steering circle.
But, I am way more satisfied with the way bike handles with DRZ400 front end than with KTM front end, so I accepted steering circle problem as tradeoff. Now, I am looking into fitting DRZ400 rear swingarm and shock to KLE.
Make no mistake, both conversions I did are 10 times better than stock KLE suspension.
Regarding the steering stem, I have CAD drawings for steering stem that adapts factory Suzuki DRZ triples to KLE frame and bearings. I suppose that factory RMZ and DRZ stems are nearly identical, so you can use my drawings as template. Send me a PP with your email address if you need them.
I also made a new front wheel axle, to mate KLE 500 front wheel to DRZ forks, and mounted KLE front fender to it using jubilee clips.
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29 Apr 2014
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Yea, turning radius is decreased with bigger diameter forks. I don't know exactly how much I have lost it but I sure did, I can feel it in the tight stuff.
Here is my total turn angle on the bars:
And how much space I have between tank and top clamp (with custom frame stops):
Now a question, for those of you who have changed the forks:
Where the  did you mount the ignition key switch? It's huge and I can't find any good spots for it.
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2 May 2014
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Quote:
Originally Posted by Ghosty_SLO
Now a question, for those of you who have changed the forks:
Where the did you mount the ignition key switch? It's huge and I can't find any good spots for it. |
Same space as before, both upper factory clamps I used (KTM and Suzuki) had threaded holes at the same location, so I fabricated two L brackets and mounted it. On my old KTM version, I even got the steering lock working, without any changes to mechanism.
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3 May 2014
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Quote:
Originally Posted by svestenik
Same space as before, both upper factory clamps I used (KTM and Suzuki) had threaded holes at the same location, so I fabricated two L brackets and mounted it. On my old KTM version, I even got the steering lock working, without any changes to mechanism.
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^The Factory thing might be my problem. I guess I will have to make the entire bracket by myself. I was hoping to put it somewhere else on the bike but that thing is so HUGE 
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3 May 2014
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Quote:
Originally Posted by Ghosty_SLO
^The Factory thing might be my problem. I guess I will have to make the entire bracket by myself. I was hoping to put it somewhere else on the bike but that thing is so HUGE |
Still consider it a small price to pay, compared with what you get  . Next project is finding a good rear shock. Tried with DRZ400 shock, but it is HUGE compared to KLE shock. Rear swingarm is too small to fit it. Might try Africa Twin shock next...
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4 May 2014
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Quote:
Originally Posted by svestenik
Still consider it a small price to pay, compared with what you get . Next project is finding a good rear shock. Tried with DRZ400 shock, but it is HUGE compared to KLE shock. Rear swingarm is too small to fit it. Might try Africa Twin shock next... |
Could not have agreed more with you on this one 
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