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The pivot bolt hole is quite recessed and you will see the brake pedal spring hole at around the "5 o'clock" position.
Pickup up a set of '99 forks and triples in mind condition as well as a '95 front wheel assembly "Complete" with brakes, axle, and spacers/washers.. I also have a set of '95 triples as well. All this means is that I'm moving that much closer to getting some "Modern" TC Forks on my '93 - YAY!
I've also received all of my new plastic as well as my graphics kit and seat cover from Throttle jockey (Thanks Chris!!!),.. I was even lucky enough to score a PlasticWerks Front number plate as well -wooohoo!
Along with the 99 forks and triples, I also bought the front and rear brake assemblies off of that '99,.. they guy just had the calipers powder coated red and rebuild - and they haddn't been installed yet.
here's a few pics of some of that stuff
I'd really like to get some more input on the Fork mod/conversion - I know CamP and a few others have done this using various methods (96 clamps and Dr.Pepper shims),.. But I think I have enough parts and materials to proceed with this swap and get things done (Thinking of boring out the bottoms of my '95 triples so the stops are correct...)
Also, I'm looking for more specific info on the rear brake up grade since I now have the '99 rear brake set up including Rotor
Thanks again!
Rick
The Shop
So,.. who's done the rear brake mod?...
Seems like someone over at the ATM forums had a set of '96 triples that I could basically "have",.. I need to follow up on that I guess. They're cheap enough and that way I'd have "Every" Option here on site to compare and layout to see what works the best - I'm still just in the planning process at this point,.. hoping for a bit more good weather around here to get a couple more rides in,.. then it'll be time to tear down the bike and embark on this great adventure
Make sure you don't go with a 97 CR125 disc and carrier as they are the same as a 96 CR125/250. Also the 2000 and later CR's are a completely different set-up again.
MCfan - I did read about that brake mod in this thread,.. I don't recall it going into much detail though,.. I'll have to go back and check,.. But I've got a complete set up from a '99 CR250 for that mod (See the red calipers and brackets :D ) .... I'll sift back through everything this weekend when I have a bit more time,... I know I missed the part about the banjo bolt,.. or at least didn't pick up on it,... I was more concentrating on the material removal from the swing arm to accept the Caliper holder/bracket (???)
triple clamps from all the manufacturers have to be bored to accommodate the larger
tube. This process is done to an off the shelf clamp. You can always tell when you
are getting a set of bored clamps if they are anodized, because the anodization will
be bored off. If you look at these two pictures, you can see the clamps that were
bored, and a set that wasn't.
Cam is right about the possibility of screwing it up. That's why I tell everybody, once
you find a good machinist, welder, etc., be good to them (six packs, etc.) - they're worth
it.
If I can determine wether or not there is enough interest, I'm considering in investing in
the necessary equipment to manufacture billet items like, linkages, triple clamps, axle
blocks, clutch and ignition covers, etc. The items I'm looking at would give me the
ability to reverse engineer existing pieces as well as create new ones. For instance,
if I had an OE 96 bottom clamp and an OE 99 bottom clamp, I could computer model
a new clamp that would adapt 99 forks to the stealie CR frames. I already have some
of this gear to use for the CR250 hybrid project I'm working on, but due to the start up
cost for things like a CNC mill, I'm farming the rest out.
dogger
Pit Row
I hear you loud n clear Cam,.. it makes perfect sense financially just to do the '96 thing with the shims,.. Depending on how much my guy will charge to do the '95 boring job,.. I may just try it for giggles
I don't have any mic's and calipers here,.. but does anyone know for sure if the Stem dimensions (Diameter) on the 95-96's and the 99's are the "Same",.. From what I gather there is about 3/8" that needs to be taken up on the '99 clamps/stem - Seems like if you could press on the 99 lower onto the 95/96 stem that would be the easiest and most cost effective way to ensure everything is correct,.. .. then it's just a matter of the "stops"... which is pretty basic. (???)
Yamaha Banjo Bolt: Is there a certan year(s) that are typically used for this? (Sorry,... still haven't had a chance to sift back through the previous years yet..)
the 96 and the 99, but the 96 stem is not as big around at the bottom as the 99, so it
uses a different sized bearing.
The best way to determine if the stems can be swapped is to press them out of the
bottom clamps and measure . If you can use your original stem, that would make
life easier. If you can't, it looks like you'll need to press out the bottom race and
replace it with a bearing/race combo from a 99. Obviously, the head tubes are the
same diameter since both use the same top bearing/race. Another thing you'll
need to compare is the stem length and threads.
Cam and X, Unfortunately I don't have access to a "karma seeking" machinist that
works for free. That's why I'm trying to gear up to do the work myself. Since I started
doing this, I've learned how to paint, polish, powder coat, weld, anodize, plate, and
just about everything other skill needed to build or restore a bike. The more work
I can do "in house", the more money I save and the more control I have over the
results.
By the way, looks like we've done a pretty good job of jacking MCfan4life's thread.
dogger
whoops! .... ah, I think everything here has been mentioned previously,.. we're just going into more detail on it
I believe the lower bearings are the same on the 93 as they are on the 99's (??) ... I guess I'll have to get those '96 clamps and press everything apart on ALL of them and start doing some comparisons .... I also sent an email to David about his lower triple that he used on his '96 conversion,.. he had one made from someone (Emig maybe?).. but according to that thread he was halting that project and selling everything off ... yet another option...
Still hoping to get another ride or two in this year before the weather turns real nasty,.. then it's on to "Tear Down" TIME!
The odd part is I asked them about just the Lower clamp,.. and they said they didn't offer anything like that,.. But I know David purchased one from them.... weird! ...
Using the complete 99 set up there will need to be that approx. 3/8" taken up some where such as below/above the bearings (3/16th on each end,.. or all one one side..which ever) - I think this is do-able..
One thing I have noticed as I look at my spare set of '93 forks along side the 99's is that the length from the edge of the fork cap to the center line of the axle is about 1/4" or so longer on the 99's - Now I'm not sure how much a 1/4" would matter in the whole scheme of things on the front end, but it doesn't look like there's much room to raise the forks up in the triples either do to where each clamp rides on the outer tube (?) .... and more so the 93's have that fine line about a 1/4" down or so from the fork cap to line up with the top of the clamp,.. so that puts the bike about almost 3/8" or taller stance theoretically using the 99 set up .... (???)
Sorry to beat this dead horse into the ground with this whole fork subject, but it seems like a lot of guys have done this or at least attempted to do this mod with good results, and I'm sure Im super over analyzing things, but I want' things to be as "correct" as possible when it's all said and done...
bearings). The 99 has the same part number top and bottom which is the same part number as
the top bearing on the 96. Best to take a caliper and measure the OD of both stems, top and bottom.
Like I said earlier, if the 96 stem will fit, that's your best bet. If you have to use the 99 stem, I would
take it to a machine shop and have the threads lengthened and the excess length cut off until it
mimics the 96 stem.
Don't worry about the additional length of the fork if you're only talking about 1/4". First check the lugs on
both forks to see if they are the same. If they are, you can easily move the forks up in the triples 1/4" to
compensate. The important thing is both forks are the same length.
dogger
As today has been pretty much dedicated to getting a game plan and solution to this whole fork episode,.. I found some more info that confirms that the 98/99 triples will work with some minimal shimming and a bit of material removal from the Steering stops on the lower bracket/clamp.
you been check'n ur email? :D
I doubt you will get a response.
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