Front fork conversion for BW200 or BW350

[Doink]

Hi,
I am interested in changing the front forks on my BW350 and I see on here a lot of people talking about CRF forks or Tri-Z triple trees and triple clamps and so on. Can anyone explain to me exactly what I would need to buy to make the conversion? I know my way around my bike, but detailed info would be much appreciated!
+Doink

[Vealmonkey]

I put the whole tri-z front end on my bw200 and I really wasn't happy with all the rake. I sent my stock bw200 front triples to a member on here, Mike at HRE atv. He bored out my triples to the tri-z fork size. I just haven't had a chance to put them on yet. So the bw will look stock, but have a front disc brake. You can use the whole tri-z front it, it's just a bolt on. Even the stock steering stop works, but it doesn't have quite enough thickness on it for me, so that has to get built up a little and trimmed down to look nice. You need the whole tri-z headlight assembly and the light switch set up as well. The tri-z has the same 3 pronged socket that the bw200 has, but it only has one. So you either run one light at a time or you have to splice into the bw200 harness to run both lights. I wasn't sure if the bw200 lighting coil was enough to run both lights, so I never hacked into the stock harness. But that front rake is a bit much. So I'm going back to the stock triples, just bored out for the tri-z forks.

[Doink]

Is there a way to just use the Tri-Z forks and the disc brake without changing anything else?
Also, has anyone attempted to get a rear disc brake on a BW?

[Vealmonkey]

Doink, read the thread. I'm changing back to the stock bw200 triples, but I had to get the bw200 triples bored out to fit the tri z fork tubes. The rear disc would be harder since you would have to fab mounts and possibly use a different rear brake pedal plus you would have to source a master cylinder, brake caliper and hose and such. But is should be possible.

[Doink]

I did read the thread. My question was in regards to the disc brake and what was needed on the bars. I'll try to be clearer next time. As for the rear disc, I wonder if the drum could be deleted and use a sprocket mount to hold the disc in place. Mount the caliper to the swingarm? Making a brake pedal that can deal with the rear travel is the only thing I can't picture.

[Vealmonkey]

You will need all the stuff for the tri-z, fork tubes, hub and disc, axle, caliper, master cylinder, brake hose and brake line guides. The front wheel and tire are the same. Just use the triple trees, handle bars and all the light stuff and switches from the bw200. The center points of the fork tubes will be the same, but have to bore the diameters of the bw triple trees out to match the tri-z tube diameter. I never put much thought into the bw200 rear disc swap. You would have to fab alot and a disc is more effective on the front.

[640AK]

Doink,

You can use your stock headlight cowl and the steel mount just by ziptying it to the Tri-Z fork tubes. It sits a little low if you rest it on the fender, but works acceptably. I stuck a little strip of rubber on the fork tubes to prevent abrasion. It is a little cheesy, but it gives you an easy place to put the key switch and neutral light and not have to hack into your harness.

However, the twin headlight setup from the Tri-Z looks totally cool. And it is easy to cut two holes into the top of the Tri-Z light cowl to place the neutral switch and key switch. Maybe you're more of an electrical engineer than I am.

Regards,

Mr. BigWheel

[Doink]

The twin headlight setup would be nice, especially when I ride/camp and sometimes it gets dark unexpectedly quick. Wiring them in would be no problem, and the key/neutral switch would just require some accurate keyhole sawing.

Regardless, I'd need to get the BW trees machined out and I guess it's my hesitation that makes me question everything. BTW, how is the rake affected with the Tri-Z tubes on a stock BW tree?

Doink

[Vealmonkey]

The tri z tubes on the stock bw triples will be at the stock rake. The tri z rake is farther out front, but only with the tri z triples. If you use the stock bw triples, you can use all the stock bw headlight stuff. If you want tri z headlight shroud and stuff, let me know as I have all that. I krylon fusion painted the tri z headlight shroud whit, I have a new tri z light switch, I have the light assemblies and the tri z shroud guard as well. I won't need them for the stock bw200 triples. The pics I posted are the tri z triples and parts and you can see how far out they are. You can send your triples up to Mike at HRE in PA, that is who bored my triples out. Since I've taken those pics, I've added a nos tank, nos side covers, and I have a nos front shroud and a nos headlight mount and a bunch of other little nos parts. Wish I could find a nos front and rear fender. My exhaust is an old nos Pro Tec pipe with a custom mounted Universal 3" Supertrapp. The exhaust easily weighs 1/3 less than a stock exhaust, sounds great, is a little tunable and lets the bw200 breathe nicely. Had to jet the carb up, of course, but she feels a little peppier by the seat of the pants dyno. Was thinking or running a hotter cam as well.

[640AK]

Doink,

I think if you want to put a disc brake on the front with the least effort, I think that the Honda 200x front end will fit right onto your BW. It is 33mm and should fit right into the Yamaha triples. You'll probably get a slight increase in the suspension performance and all the coolness that comes with upgrading to a mid-eighties disc brake. The fork for the 200x is a little longer but I think you could get away with sliding the tubes up the triples and keep the bike fairly level.

Just a thought.

Regards,

Mr. BigWheel

[Doink]

Thanks. The 200x does sound a lot less hassle. Now, just gotta find one with the d brake included. Then get the master cylinder and the brake hose and the caliper and the ... anything else I fergot?
-Doink

[640AK]

An axle would be handy. And spacers.

You'll also need a hub. Then you'll get to replace the 20 year old rusted out bearings and rotten seals in the hub.

New seals for the fork tubes (that are probably bent, like 90% of the ones on ebay) and bushings since you're already in there. Don't forget the overpriced dust seals.

The caliper and master cylinder will probably be seized and in need of rebuilding. The hose will probably be filled with gunk. No problem! You'll already have all of your tools out.

Now you'll just consult the Honda maintenance manual for the 200x for the rebuilding procedure and you'll be done! You do have a 200x manual, right?

This near-vintage stuff is fun!

Regards,

Mr. BigWheel

[Doink]

So, piece of cake is what you're saying? Ah, your sarcasm is like a warm embrace.

I can't wait to go through it all and then dislocate my shoulder when I grab the fronts and go ass over teakettle.

[Husky250]

Doink,

I think if you want to put a disc brake on the front with the least effort, I think that the Honda 200x front end will fit right onto your BW. It is 33mm and should fit right into the Yamaha triples. You'll probably get a slight increase in the suspension performance and all the coolness that comes with upgrading to a mid-eighties disc brake. The fork for the 200x is a little longer but I think you could get away with sliding the tubes up the triples and keep the bike fairly level.

Just a thought.

Regards,

Mr. BigWheel

Well I have the "X" front end, all I neeed is the BW!

[Doink]

Or vice versa. You looking to sell?