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Old 07-02-2012, 05:23 AM   #1
Cumbacheech OP
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USD fork conversion XR650L

Hi Everyone,

I just picked up a set of USD forks for my XR650L. I have started to gather information to help me out with my conversion/installation. I figured that I would start up a new thread so that I do not clutter up the XRL thread and also use it to share/gather information. It would also be cool if people who have already done the conversion would share some of their findings and some of the problems they encountered and how the resolved them.


Some things that I have already learned about the conversion:
Can’t use the XRL wheel
CR/CRF uses the same brake caliper as the XRL
The XRL brake caliper is a direct bolt on for the older CR/CRF forks (pre-2004)
Newer CR/CRF forks (2004) will require a new bracket to mount the caliper
Steering stem will need to be machined in order to fit on the XRL
There are triple clamps from a couple of vendors that will allow you to use the stock XRL stem
There is one vender that sells a steering stem that is already machined (basically a plug and play)


Cheers ,

Cumbacheech
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Old 07-02-2012, 06:40 AM   #2
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OK, I'll start. I have done a few CRF to XR/XRL conversions and have done it a couple different ways.

For my XR600 I used 2002 CRF triple clamps a friend gave me (FREE) and since I found the Emig Racing conversion stem http://www.emigracing.com/CRX46.htm it was a bolt on job. CRF triples, Emig stem, CRF-R wheel (without the ODO drive) R axle, CRF caliper. Since I didn't have the ODO drive I needed the R axle as a CRF-X axle is different on the right side due to the ODO drive assy not taking up space or being a spacer. I have one of the Honda enduro computers but with the CRF handle bar bolt pattern being wider then the XR I had to go with a Vapor computer.

Now on to my XRL. RSW Racing triple clamps were the order of the day. Direct bolt on using the OE XRL stem which retains the speedometer assy, ignition switch/fork lock and headlight. This time I found a CRF-X wheel to use the ODO drive and cable that attaches to the XRL speedometer and a X axle










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Old 07-02-2012, 06:50 AM   #3
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That rocks Steve! thanks for sharing!

Quick question about the steering stem, how do I get it out of the triple clamp? I heard that it needs to be pressed out from Top to Bottom, Is that correct? and if it needs to be pressed out where can I get that done?

Cheers,

Cumbacheech
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Old 07-02-2012, 07:26 AM   #4
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The first stem I pressed out was my buddys XR400 and I pressed it from the bottom to the top. Whoops. Took it to my machinist , pressed it back in place and he TIG welded the bottom. Filed smooth and no one was the wiser.

So when I did the CRF jobs the stem gets pressed from the top out through the bottom of the triple clamp. Again I went to my machinist to use his press and when I did my XR the press was at max pressure before it popped loose with a bang.
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Old 07-02-2012, 08:07 AM   #5
Deadly99
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I could make it easy for you, I have triples, front brake and a set of Showa forks (from crf450). The kit is a direct bolt on for a 650l. It's collecting dust, I'd planned to get an L but ended up with an R. Shoot me a pm if interested
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Old 07-02-2012, 08:12 AM   #6
elsalvadorklr
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heres a little refresher course, same same for xrl...

http://advrider.com/forums/showthread.php?t=774934

although like you mentioned some year cr/crf forks need no bracket(thanks steve)

other than that a shim here, some bushings/sleevs for the stem here...

good luck!
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Old 07-02-2012, 08:14 AM   #7
elsalvadorklr
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Quote:
Originally Posted by Cumbacheech View Post
That rocks Steve! thanks for sharing!

Quick question about the steering stem, how do I get it out of the triple clamp? I heard that it needs to be pressed out from Top to Bottom, Is that correct? and if it needs to be pressed out where can I get that done?

Cheers,

Cumbacheech

that is correct, there is circlip that prevents the stem from going up!

so press down and then back up till circlip stops it cgoig up aywmore...

there is a pic on my thread showing just that

use steel sleeves if using your xr stem
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Old 07-03-2012, 02:51 AM   #8
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Hi All,

Since I still need to get a brake caliper mount I was wondering if it would be a good idea to put on a oversized 320mm brake rotor on my dirt setup. I was thinking of doing this so that when I switch back and forth from my Sumo setup I don't need to change the bracket everytime. Is this a crazy idea?

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Old 07-03-2012, 12:21 PM   #9
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Hi All,

Is there a trick to removing bearings from the steering stem? I have never replaced my bearings so this is new for me. Should I use OEM bearings when I do the conversion or should I use an aftermarket one?

Cumbacheech
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Old 07-03-2012, 12:47 PM   #10
elsalvadorklr
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did you read my thread? all the info is there man

just press the stem off down wards...and the bottom bearing will pop off the tapered stem

then just tap it back on on the xr stem once you make the bushings to fit in the cr lower clamp

or if using the cr stem you have to turn it down and then tap the lower bearing onto that
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Old 07-03-2012, 01:49 PM   #11
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Quote:
Originally Posted by elsalvadorklr View Post
did you read my thread? all the info is there man

just press the stem off down wards...and the bottom bearing will pop off the tapered stem

then just tap it back on on the xr stem once you make the bushings to fit in the cr lower clamp

or if using the cr stem you have to turn it down and then tap the lower bearing onto that
I read the whole thread and picked up some good tips, Thanks. I am thinking that I might be able to get the stem turned with the bottom triple clamp on. That is why I was asking if there was a trick to getting the bearing off without removing the stem. I read on some threads to use a chisel to pull the bearing off.... I don't want to do that so I was wondering if there was another way.
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Old 07-03-2012, 02:41 PM   #12
elsalvadorklr
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gottya

yeah if you do its best to replace with the same new bearings...you will damage the bearing cage as its quite delicate...

you can reuse only by doing it the press off way

if you want to turn down the cr stem its best to just break off the lower bearing, also the seal is under and more than likely you will damage that

I re-used my bearings and seals since they had maybe 5k miles on it from my last full rebuild

also most bearing shops will have these bearings just take the samples, seals maybe not so lucky

cheers
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Old 07-03-2012, 03:35 PM   #13
mcma111
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When I did my '91 XR conversion I bought new E-Bay bearings. Hell, a bearing is a bearing for the most part. On the XRL I reused the OE. The only good, safe, clean way to remove the lower bearing is to press the stem out. No damage to anything in the area. Just the way it is. Reuse the lower seal and bearings depending on how old/miles are on the bearings. Before installing the new/used lower bearing be sure to grease the shit out of it with your favorite water proof grease.
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BMW's
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79 R100s
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87 Harley FXRS-SP ~ 06 KTM 625 SMC ~ 72 Honda CB750/915cc ~ 92 XR600/654cc ~ 95 XR650l/675cc ~ 03 CRF450r ~ 05 CRF450x ~ 02 XR650l/675cc ~ 86 YZ490 ~ 93 YZ80 ~ 93 XR650l Project
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Old 07-06-2012, 03:59 AM   #14
Cumbacheech OP
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Hi Everyone,

I was just wondering if it is possible by just changing bearing sizes and adding a bushing to the top clamp you could get around machining the stem.

I was looking online and I found out bearing information online as follows:

Inner diameter x Outer diameter x Width
XR650L 26 x 47 x 15
CR250R 30 x 51 x 15
So if it is possible to locate, I would assume that if I could find bearings that are 30 x 47x15 than those should do the trick…

Has anyone tried this?
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Old 07-06-2012, 06:58 AM   #15
elsalvadorklr
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you could, cept I remember people not being able to find an exact match

the easiest is reusing your xr stem., that way you reuse your stock bearings and dont have to buy anything!

turning down the cr stem is more involved and makes you have to buy new bearings...

anywhoo

good luck
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