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PAdr650Guy

DR650SE / Yz450f Fork Swap

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Posted (edited)

I have a 2013 DR650SE, with heavy springs and intimidators because I ride to the trails and do a lot of off road, I have decided to do the USD forks.

Luckily, I already have a set of 2004 WR450R 48mm forks and Triple Trees.

I plan to keep the front end as close to the DR as possible by using the DR wheel. Since I have not seen anyone convert the original hub to a 20mm axle I figured I would try.

Stem: I purchased the All Ball bearing conversion set for this. Will use a spacer or Press DR stem onto YZ bottom clamp

Wheel: I ordered some 20mm x 35mm x 9mm wheel bearings to replace the 17mm x 35mm x 10mm. 

Fairing/mounting: I purchased a set of DRZ light brackets to mount everything. Will customize mounts for Ignition Switch and Dash.... 

Brake: I also ordered a 270mm Rotor bracket for the YZ forks and a 270mm rotor. DR Caliper mounts to the forks.

My main issues will be  rotor and wheel spacing.

As I work through this I plan to post pictures of the build to assist others.

I would prefer to keep the stock speedometer and thought about swapping the speedometer assembly box with the DRZ since it is 20mm.

I know I could machine a top hat for the DR axle and that will be plan B if I cannot make it work on the YZ 20mm axle. If you have one I would buy it 🤪

Plan C, will be use a YZ front wheel and get a digital speedometer.

Obvious I could change the hub, but that wouldn’t be as fun😉

Any advise would be greatly appreciated!

Edited by PAdr650Guy

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Yz450f stem is 30mm and so is the DR stem. However the YZ stem is about 15mm too long so rather than using a spacer I am going to press out the YZ stem and swap it for the DR stem. 🤞

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I am interested to see how it turns out. 

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The DR650 stem fits perfectly in the YZ triple. This eliminates the need for a spacer, and allows you to use original DR650 Bearings

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Need to buy, one inch bar rises to clear the forks. Also, eliminated the stock ignition switch, will replace with DRZ.

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Slowly making head way. The bracket I bought doesn’t give me enough room for the stock rotor, so I will have to make an adapter.  Ran the speedometer cable and brake cables nicely with the YZ forks.

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The pro cycle Dash relocation bracket and light mounts for turn signals are going to work perfectly for these triple clamps.

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Users some angle aluminum to mount the speedometer, to the same area as stock. Not sure if I’ll keep, it like this or not. Lastly need to mount the ignition.

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very nice! the only negative of such projects is that as soon as youll start off-roading, youll notice how much the rear shock sucks 🙂

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Rather than manufacture a brake caliper adapter from scratch I purchased the YZ450F 320mm. Obviously this bracket is too large. I Then purchased a m8x1.25 tap, and 2 m8x30mm stainless bolts as the stock DR650 bolts where much too long.

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Posted (edited)

Project Completed. Issues I ran into was mostly just Fabrication of the brake bracket, and mounting the speedometer and dash lights to new triple trees.

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Edited by PAdr650Guy
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On 4/23/2020 at 3:37 AM, turboguzzi said:

hit any trails yet?

Yeah it’s night and day, I am so happy with the turn out. 
 

also I reworked the dashboard, and forgot to post a picture of that. I used a Suzuki Boulevard ignition rather than DRZ. The Boulevard is literally plug and play.

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Fyi: the front wheel required a 4mm spacer between the right fork and the speedometer hub assembly. 

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