RATEL engineering design - BMW 650GS/Dakar/Sertao YZ/WR suspension upgrade

Discussion in 'Vendors' started by Aquatic, Feb 3, 2014.

  1. Gravel Seeker

    Gravel Seeker Old, growing older.

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    :thumb
  2. Aquatic

    Aquatic Long timer

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    First thing to do is fix the root of all the bearing evil. The hole in the spindle. Which ever engineer thought that was a good idea is a fickwit!
    20200327_113815.jpg

    Some 3M tape and problem sorted
    20200327_113959.jpg
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  3. Aquatic

    Aquatic Long timer

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    Took a bit of effort but I managed to get the old bearing off without cutting it.

    I couldn't find any new seals, but the old ones are still in excellent condition so I'll reuse them
    New bearings - sourced locally
    High temp grease - because the oil is in the frame and the neck area can get quite hot
    20200327_114741.jpg

    greased up bearings
    20200327_115555.jpg

    In the press
    20200327_115801.jpg

    Lower bearing installed
    20200327_120317.jpg

    I didn't take any pictures, but the outer races were installed in the head.
    i used threaded rod and some made up spacers that fitted the races perfectly
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  4. Aquatic

    Aquatic Long timer

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    A quick test fit of the forks
    20200327_121317.jpg

    Headlight and handle bars all back together
    20200327_130113.jpg
    Dummy axle just to check
  5. Aquatic

    Aquatic Long timer

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    I measured up the fork and and then redesigned the existing caliper hanger to suit the new dimensions
    TEST ASSY.PNG
    TEST ASSY 2.PNG

    I 3D printed the new caliper hanger to do the test fit
    Fits exactly as planned
    20200403_124726.jpg
    20200403_124754.jpg
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  6. Aquatic

    Aquatic Long timer

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    Looking good so far.

    Next item of business is to redesign the suspension knuckle to raise the rear the same as the front
    20200406_004423.jpg

    I'm hoping to make an adjustable unit.
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  7. Christoslazy

    Christoslazy Adventurer

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    Hello! What is the doner bike of this USD system? I am looking forward to doing the USD transplant on my DAKAR and I have been offered a system from a 2009+ KLX250S and another one from an Aprilia RXV 450! Any suggestions on which one to prefer according to the ease of the process and the performance? Do you offer any caliper hangers for these? Also do you offer any redesigned knuckle for the Dakar in order to raise the rear and increase the wheel travel (with the same stock shock)! Thanks!
  8. Aquatic

    Aquatic Long timer

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    I think Kawasaki also use KYB.
    These off of a Yamaha yz450. Not sure what year.
    They are the SSS closed cartridge forks
  9. Christoslazy

    Christoslazy Adventurer

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    OK, thanks! Yes Kawasaki forks are KYB for sure! Do you think it’s better to go this way instead of the more exotic aprilia way (48mm)! And what about the altered Dakar knuckle question? Thanks again!
  10. Aquatic

    Aquatic Long timer

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    I cannot help with a conversion kit for the Aprillia.

    Raising the rear of a Dakar is done with shorter links.
    I have in stock
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  11. Gravel Seeker

    Gravel Seeker Old, growing older.

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    will the shorter raising links level the rear with the WP forks as well? Think they're 930mm.
  12. Aquatic

    Aquatic Long timer

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    Not sure how much longer 930mm is.
    But the links will raise the rear ±26mm no matter what you do up front
  13. Gravel Seeker

    Gravel Seeker Old, growing older.

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    Does that mean the KYB's raises the front by 26mm?
    Stock is 890mm I think in which case the front has been raised ~30mm (I checked my notes and I've measured the WP's ca920mm from top to center axle (917-920 difficult to measure exactly)).
  14. Aquatic

    Aquatic Long timer

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    I'm actually no longer sure how much the front gets raised. I used to know.
    If I recall, reducing the length by 25mm still gives you 25mm longer forks

    I will measure when i get a chance.
    I have 2 sets of open cartridge and 2 sets of closed cartridge
  15. Gravel Seeker

    Gravel Seeker Old, growing older.

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    Yeah, my WP4860 forks are 950-960mm long center to top so it's not unreasonable that the KYB's are around the same length.
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  16. shortman

    shortman Beta 500 RS, X-Trainer 250 Supporter

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    @Aquatic

    Do you have the ability to lazer cut a replacement tone wheel so that the speed O can be calibrated? There is an old Cafe Husky thread:
    http://www.cafehusky.com/threads/tr650-speedometer-question.45888/

    That has a guy who had some made to correct his speed O error.... I have tried reaching out to him and all I get is crickets....

    Below is a picture of what his looks like... I only need the rear wheel one cause my bike doesn't have ABS.... The washers are to space it off the wheel. Please let me know....


    ToneWheel.JPG
  17. Aquatic

    Aquatic Long timer

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    Leave it with me
  18. shortman

    shortman Beta 500 RS, X-Trainer 250 Supporter

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    So does that mean you’ll make one (or more)? I’m sure I’m not the only one who wouldn’t mind correcting the speed o meter error.....
  19. Aquatic

    Aquatic Long timer

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    :beer
    :thumb:thumb
  20. Aquatic

    Aquatic Long timer

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    20200430_003234.jpg

    Now to test. From Saturday we are allowed to go for a ride. 50km radius from home:clap:clap:clap
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