F800GS "Drop-In" Fork Replacement?

Discussion in 'Parallel Universe' started by PenultimateMan, Oct 5, 2012.

  1. FredRydr

    FredRydr Danger: Keep Back 500 Ft.

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    I'm in Hendersonville NC (home of Ohlins USA) for work on the NIX suspension and shock of my F800GS. I just spoke with Gary Christopher, Ohlins USA Service Advisor for motorcycles, regarding my own bike's issues, and when we finished, I asked the very questions being posed here, especially in the context of the title of this thread. Take note.

    The forks do not have to be machined as of course. On the other hand, the Ohlins NIX cartridges are not "drop in." Adjustments to the OEM forks are routine to enable proper fitment and operation of the cartridges. These adjustments might be, as he called them, "no brainers" to experienced and equipped technicians, but fitment cannot be accomplished by simply "dropping in" or "bolting on." He summed up that this will be especially true with the new forks on the 2013 F800GS because S&W is notorious for variations or inconsistencies in their production.

    Alas, the technician who was to do the work on my bike was injured in a crash in a moto race over the weekend, so I'm waiting to hear if I'll be heading eight hours home without the Ohlins work being completed. I'm optimistic, though.

    Fred

    P.S. The work was completed after all, and I've been having a blast on a much-improved ride, on and off pavement!
  2. bxr140

    bxr140 Flame Bait

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    Diameter no matter, just need to turn a stem. :deal
  3. MCMXCIVRS

    MCMXCIVRS Long timer

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    Thanks for that bit of info. It would seem then that the insets I got are the same ones that they install down there. It'll be interesting to see the difference (if any) to the new setup once they are out.
  4. itchy&scratchy

    itchy&scratchy Twins, Bazil

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    So after all these pages, I'm getting that my F800 forks cannot be modified, instead I have to change over to completely different brand of fork, wheel and so on?
  5. Rider 101

    Rider 101 Highly paid idiot

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    Itchy,
    I have had my 800gs for 2 years now. I racked up the 5000ks yesterday. I did a loop out to Coolah Tops and returned via Blackville and Willow Tree - Merriwa road. The road varied from tar to roughish NPWS tracks. I think my max speed on gravel was 110k's. I didn't push the bike above 80k's on the forest road and slowed to 30 or 40 in the rocky sections. I was carrying 4 litres of fuel, full Motohansa tool roll, tyre pump and a backpack with food, drink emergency kit. I am no lightweight ( 100kg ). So add that up and I guess I am adding 120kg's to the bike. I feel the suspension coped with my style of riding. I am 51 and need to go to work on Monday in one piece.

    I suppose what I am getting at is that the 800gs performs as it was designed. After reading a lot of these threads I came to the conclusion that any shortfalls in the suspension, wheels etc are highlighted by younger fitter or better riders than me.

    I will be looking at changing fork and shock springs to cope with a little extra weight but I very much doubt I will be pushing ( or able to push ) the bike beyond its capabilities in standard trim.

    I hope this helps you enjoy your bike for what it is and don't get caught up in spending bulk dollars on something that may exceed you capabilities.
  6. machinebuilder

    machinebuilder Long timer

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    If you look at some of the other suspension threads there are a few options available that are replacement cartridges that do not require modification.:deal


    Yes you can ride it as built over a lot of different terrain, BUT better suspension will make it easier to do.:D
  7. FredRydr

    FredRydr Danger: Keep Back 500 Ft.

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    You're "getting that" wrong. That's often the problem with internet forums, where conflicting opinions leave the reader confused. Contact a suspension specialist for a concise description of what can be done to upgrade your F800GS forks.

    I strongly disagree that upgrading suspension risks wasting money because it is "something that may exceed your capabilities." On the contrary, a properly set-up quality suspension will make riding in difficult terrain easier and much more fun for anyone, especially a novice.

    Fred
  8. MCMXCIVRS

    MCMXCIVRS Long timer

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    Just home from my Rawhyde trip through Mojave and Death Vally. Wow, what a difference the Ohlins made to the bike. Lots of rough terrian and sandy woops on the route. The suspension handled it like being on a cloud. Lots of compliance, but never felt any harshness. I did find it a bit floaty feeling on the asphalt, so may need to dial in a little more rebound dampening on the rear.

    FYI, I'm 48 and am also not as young and fit as many F800GS riders here, but the upgrades still were well worth the cost for me. The bike is just so much better now than with the stock setup. :clap
  9. PatrickM

    PatrickM Been here awhile

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    With many threads on the subject, and am not quite sure where to post this - so thought I'd use this one :)

    The 2013 F800GS uses a 43mm WP fork. Talking to the KTM guys and it looks like some of the older KTM's used a 43mm fork as well.

    Would the WP 4357 (43mm) work and/or be a drop in? It apparently was used in a variety of bikes and had the compression and rebound settings (top and bottom) that the Shiver replacement for the 2008-2012 are taking advantage of.
  10. Hamish71

    Hamish71 Been here awhile

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    Actually itchy, that is not true.
    I have found someone that can pull the crimped Marzocchi cartridges apart and rebuild them. Melbourne guy, PM for more details.
  11. itchy&scratchy

    itchy&scratchy Twins, Bazil

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    Thanks Hamish for the offer. My bike has travelled 25K prior to me and alot of it off road, so I suspect and know the fronts need replacing.
    I was travelling on a sand based forest road yesterday and when coming into soft sand the front end wanted to wash out every time, so I'm hoping a remake will provide me with more positive feedback in these situations.
    Cheers
  12. Gangplank

    Gangplank Advenchaintourer

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    Sounds like the process would be the same then:

    1) buy donor forks
    2) use internals from donor forks
    3) have stock BMW fork bottom lugs machined to accept the comp. adjuster
    4) use top cap & internals from donor fork & have it valved & sprung for your weight.
    5) if they are same length travel as BMW then no changes needed. If more travel they can easily be shortened internally by adding a spacer.
    6) Bolt it back on and ride.


    Posted mobile on Tapatalk
  13. Konflict Motorsports

    Konflict Motorsports KM TUNER

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    The 43's are not a drop in, nor are the 48's. The BMW WP fork lugs do not share the same inner cartridge step as the 45mm zokes. The inner bore needs to be machined to accept the updated cartridge. Also, the fork caps are not a direct fit, either the 43mm or 48mm.
    I have done it, and offer the 2013 fork conversion but it is a lot more labor intensive than the 45mm conversion.
  14. Snowy

    Snowy Long timer

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    I could try quoting multiple sources here but what it boils down to is this:

    1. You can try doing the donor fork internals thing and keep the original brakes, triples etc

    2. You take the plunge and do an entire front end change out.


    No, you wont make the bike out perform you.

    Yes, the bike will do the basics as standard with some simple cheap mods.


    But doing it properly will make it so much better to ride that you'll start taking it places it really shouldn't go. Then doing things it really shouldn't do. You'll look at a track and think "Yeah...I can get up that".

    That's when the adventure starts.

    That's what's it's supposed to be all about. Giving yourself the best shot at getting out there and back in one piece and living the dream into the bargain.

    With the F800, BMW got so close....I got closer.
    clax likes this.
  15. djborden

    djborden Been here awhile

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    Any more options surface for converting the 43 mm WP forks on the 2013 to adjustable going the donor route?
  16. Rider 101

    Rider 101 Highly paid idiot

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    Talk to Traxxion Dynamics. I did their AK20 drop in cartridges and couldn't be happier. Left leg has compression and right leg has rebound. The whole change-over only took about 2 hours ( but could have done it a lot quicker ).

    No machining, no modifications, just simple follow instructions and job done.

    The end result was well worth the $1400 US

  17. James Siddall

    James Siddall suspension guy

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    Guys,
    The Ohlins FKA kit is now a production item, greatly reducing the cost. This is a complete NIX Fork cartridge kit, fully adjustable and amazingly capable.
    Available for both the 2013 WP forks and the 2012 and earlier Marzocchi. $1467 with springs. Don't overlook this option.

    Cheers

    James
  18. Rider 101

    Rider 101 Highly paid idiot

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    James,
    I looked at the Ohlins a couple of months back before I got onto Traxxion. Unfortunately the price to me was AUD$2200 which was way above the AUD$1600 I paid for the AK20.

  19. clax

    clax Been here awhile

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    Anyone have a part # for the Ohlins 2013 WP fork kit?

    This thread is kinda old. Are any other options surfaced? Has anyone tried the Andreani cartridges Ive seen on ebay?

    thanx
    C
  20. Loutre

    Loutre Cosmopolitan Adv

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    +1 on that. I did some mild offroad before changing all these components. had some spare cash on hand and wanted to see what all this suspension fluff was all about and was fed up with fork/suspension behaviour whilst two up or traveling under load. The result is simply mind blowing and makes you able to take that bike to places you never thought you'd explore. They become even better and wayyyy more fun after these mods. I know you read alot of crap on the internet and dunno what to trust but believe me that suspensions are what you can do best on any bike.