In this thread I will try to show how we can upgrade our bikes with new front forks.
Long story short winter was long and after seeing JaumeV - traildreamer and Ni3ous what they did with their bikes I started project for upgrade my front suspension of Tenere.
What do we need:
- complete front end from bike with better suspension,
- someone capable of technical work (press, lathe),
- a lot of time for browsing internet.

I started with front end from YZ250F 2008:



Buying complete front end from KTM - WP 950/990 would be better solution - two front dicsc without need to modify, revalving forks not needed. But it would be much more expensive and more difficult to find.

I could not find wheel with black rim to match with back wheel. So I gave up and have original excel rim powder coated in black.

Front brake:
My first idea was to use original brake caliper with Honda pads and 320mm oversized rotor from motomaster. They are selling rotor and adapter together. Problem is that this type of rotor is only 4mm thick and when I realized that original Tenere rotors are 4,5mm I decided that brake power will not be big enough.
Luckily I found used complete motomaster front brake set (MC/line/caliper) for good price. So I just ordered new caliper bracket and motomaster rotor.
The biggest issue if you want to use 4 piston caliper on YZ fork is that it will not fit with usual mounting bracket - it will hit spokes because it is too wide - you need to move it with rotor at least 3 mm from spokes.
So I have to manufacture special mount for front rotor with 3mm thickness. This was difficult as we wanted to keep inner center diameter for rotor. After some thinking this might not be necessary and can be just laser cut from 3mm thick material without inner centring diameter as rotor is holding mainly on screws - saw this on most KTMs.




Some pics:
YZ vs Brembo (original tenere)




YZ vs Motomaster




Progress so far:


In the meantime I also ordered some fork protectors and new tyres.

Next thing is how to mount all this onto Tenere:
I mostly copied what Ni3ous did so I used original steering stem from Tenere and used it with YZ fork clamps. This is time for work with press
Also I used original head bearings from Tenere. Bearings from YZ will not fit.
In the picture bellow is final product:



After this you can mount new clamps with fork onto bike. Thing is steering stop was in wrong place for YZ2008 clamps so I have to manufacture new steering stop so fork will not touch radiator:



Now I thought that I can do test ride on upgraded Tenere.
This was time when I wanted to try original springs in YZ forks which are surprisingly quite strong.I basically wanted to change oil in forks and cartridge and test sag measurements and maybe try another set of springs I have.

YZ forks disassembled:




But I found bad surprise - broken free pistons:



This is known issue for YZ forks 2007-09.
These are essential for damping and quite expensive. I used new aluminum ones so they can not brake like the old plastic ones:




After this it was finally time to do test ride. Final product so far looks like this:



- front fender from YZ250F 2008
- needed to use bar risers to match original Tenere high because YZ bar clamps are just 2cm high. Front end is higher due to fork anyway so this is ideal for me.
- new KTM handguards and right mirror will be fitted soon,
- I have to create new steering lock on YZ clamps.

This setup is working best on fast dirt roads. Revalving is neccessary to achieve more comfortable front fork on tarmac roads.
I had also problem with bleeding front brake but strap on the lever for night fixed issue. Now braking with 1 finger is ok, 2 finger braking is destroying front tyre

As everybody I also noticed now how bad is rear shock so next turn is changing this one for some aftermarket - FMX, ohlins,wilbers maybe.

I want to thank JaumeV and Ni3ous who did this before me and put their work on our web. I would not known about this possibility without them.
Thanks.

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Yamaha XT 660 Z Tenere

Well done, looks a very neat job.

Good work! Is it not too much that caliper off road?

Maybe you feel the same as me before revalving, it�s hard and harsh when normal riding, you can feel every little hole in the road like a punch.

With the new set up at first it is soft but then it hardens.

Ernesto, it is radial MC so it has really nice feel. I was a bit worried how this will work but now I like it more then original brakes.
Revalving is needed for the fork thats for sure. I need to find somebody who is doing supermoto racing or some experienced suspension guru. I think that shims needs to be changed but I dont know for which ones
Maybe I will read racetech suspension bible to the end and try it myself.

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Yamaha XT 660 Z Tenere

Excellent walk-through and pictures. You've done a good job with it.

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