Bad luck maxwell, think I'll keep an eye out for one on ebay 'just in case' ..... not had to have the front wheel off mine yet....
SelinaXT

Maybe you can play with old fork trying to weld and in some way change whole design and finishing without use of any pinch bolt?! Different axle design?

Thought about getting completely different forks from another bike but would be too much of a hassle.

As for changing the design it wouldnt be to hard if it was steel but its alloy which needs a proper mechanic/technical person who knows what they are doing/the proper tools to change things.

Selina
From my memory i havent seen a set of R's forks on ebay for a while, mostly X's or station tubes, not the fork legs. You havent taken the wheel off yet, you need to get some more miles on that bike and start messing about with things your self.

Hang on there Maxwell! - do you know if the forks on the R are the same as fitted to the Tenere? (other than the second caliper mount on the right leg, obviously) - if they are the same length and diameter, I just so happen to have a pair from my Ten' that you are welcome to for �100 the pair (plus postage, they are quite heavy!)

They are still in good condition, although have a few minor scuffs on the bottom of the fork legs...

Just a thought?

Jenny xx

ps. I also have the right hand brake caliper, plus the hoses and master cylinder if you fancied doing a twin disc conversion?!

Firstly, I must say that the xt660.com search function works very well :happy3:.

I got my bike (2005 XTR) in early December. After just one ride I decided I wanted new tyres and when they were reassembling the front end at the tyre place, the fitter managed to crack the fork leg clamp on the right hand fork leg :sad11:.
https://public.blu.livefilestore.com...80a.JPG?psid=1

This country basically shuts down over Christmas & New Year (Happy New Year everybody, BTW). Whilst the tyre shop readily admits liability they're not showing much initiative and we've not had any success in getting another fork leg from a breaker's yard.

So I'm going to let a work colleague have a go at repairing it using a TIG welder. He's built racing cars in the past so I reckon he knows what he's doing. I'll post again when it's fixed.

I've only ridden the bike twice :sad10:.

The fork leg has been repaired. The pinch bolts were torqued up to 30Nm to test the weld strength- no problems so far :001:.
https://public.blu.livefilestore.com...88a.JPG?psid=1

I'll obviously torque them to the regulation 18Nm when reassembling the front end.

Hello,
I am opening the topic since the same problem appeared to me also :(
Any idea where I can find a used fork end, besides ebay?
Since I could find any available in ebay.
thanks!

p.s for photo refer to: http://www.xt660.com/showthread.php?p=203401#post203401

A friend of mine who I've been motorcycle touring with over the last six or so years (not all on XTs!) suffered a cracked fork leg on his 2008 R.

Whilst we do a lot of our touring on very poor Eastern European and Asian roads (and in the UK!) these are nothing that the bikes were not designed for.

He waged a letter writing campaign against Yamaha and I think they only gave him a small reduction in the new cost of the fork leg, if only to shut him up.

Unfortunately from a little research in the local market, it seems that it is a very common problem and the used-part dealers are requesting a huge amount of money for this specific part, which in my point of view it doesn't worth to buy, since there is a big chance to have a new crack again after some time.
Since this issue is corrected in the new version of XT's, does the new one fit to older models? (mine is a 2004 model).

Hi guys fast for ward to 2016. My 2006 XT660R fork keg lower has cracked at the pinch bolts. Yamaha no longer sekl the fork leg lower on its own bit will sell the whole fork leg stanchion and innards for �500+ :-o

Local welding firms don't wanna take liability so won't weld. Asked three different firms now.

Rang breakers all over the breakers in the uk. General feedback is not many XT's broken when they are the front ends usually bought by someone pretty quickly.

Any ideas . Really like to get it back on the road unless it's worth breaking and selling to fund another XT? Help. :eusa_boohoo::boozer: p.s
Are the XT660X fork leg lowers interchangeable with the XT660R LOWERS (eg same stanchion and internal workings and spring dimensions? )