Thanks mate!

More parts coming in, I got axle inserts and top clamp insert. Due to really crappy weather :rain: 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:
http://shrani.si/f/v/gI/SBt8Rc3/img4111.jpg

And here is the top clamp insert:
http://shrani.si/f/3y/yG/rUY3K16/img4112.jpg

Now I only need to find a way to lift the bike up for the change, any ideas??:confused1:

Cheers!

Hey all!

Here are a few of my progress pictures:
http://shrani.si/t/1Z/45/8RsW18X/img4154.jpghttp://shrani.si/t/44/sP/2Iu2PoiM/img4159.jpg

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:
http://shrani.si/f/2f/ko/eC8iqa0/offset.jpg

Thanks for your help!

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.

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.

http://shrani.si/f/1f/rD/23pElRvF/img4188.jpg

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:
http://shrani.si/f/S/mb/1ngUsMR5/img4186.jpg

steerer stem dimensions
 

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

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!

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.

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!

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.

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:
http://shrani.si/f/2j/E1/ahp7D3c/imag0157.jpg

And how much space I have between tank and top clamp (with custom frame stops):
http://shrani.si/f/24/ql/2CS1azzK/imag0158.jpg

Now a question, for those of you who have changed the forks:
Where the :censored: 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.

^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 :thumbdown:

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 :thumbup1: