Milling the OEM clamps / triple tree

[Coxbow]

Hi Folks,

I'm building myself a "budget" Cafe Racer.

I'm gonna swap the front end with a shorter fork for the looks, and double disk for the efficiency, I've got a XJ900 for parts, I'm thinking about putting the whole fork in my OEM clamps / triple tree.

The OEM clamps are for 36mm tubes and my XJ900 fork has 37mm, one mm shouldn't be a problem, but how big could I go without any problems ? ( I really don't like the XJ900 wheels !!)

It looks like there's enough meat to grind some of !

https://imagizer.imageshack.com/img924/7172/5EYLdY.jpg

Thanks

[faffi]

These are cast, I believe, and hence of less strength than machined items. Personally, I would not take out more than 1mm, but if you do not plan to ride aggressively, you could probably go to 39mm ID. At your own risk, of course.

[Coxbow]

I found a XS750 front for 150$ ( well Euro...) and that's a 36mm so nothing to do ( well not on the triple tree) and no risk, and I like the wheel

https://imagizer.imageshack.com/img923/2764/4o1OAU.jpg

[Coxbow]

Somebody suggested me to use the whole XJ900 front end, that would be a great idea !

I don't have to worry about spacers that I might have to use to align the wheel, disks and brake calipers, hoses, master cylinder etc...

And I could also use the handy adjustable half handlebars present on the XJ900

https://imagizer.imageshack.com/img923/2200/51RcMB.jpg


So I need to find the bearing sizes of both forks, the external measure of the XV750 and internal of the XJ900, right ?

What about the stem ?

[faffi]

You should be able to find bearings that will work with the 900 stem, but l am unsure about the length, if those are the same.

[Coxbow]

well the 900 just has to be long enough or longer !

so all I need are bearings with a inner side the 900 stem diameter and at the outside the XV frame diameter and that's that ?

[faffi]

Yes. You may or may not have to modify the steering stoppers and/or the placement of the ignition switch, though.

[Coxbow]

Found my bearings, here's a great site for that: https://www.allballsracing.com/index.php/forkconversion

The steering stoppers and ignition switch is nothing.