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General Category >> Rubber Side Down! >> Replacing Forks
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Message started by NCSUindy09 on 09/28/23 at 18:28:23

Title: Replacing Forks
Post by NCSUindy09 on 09/28/23 at 18:28:23

Hi all,

My 86 savage has been sitting in the garage for a few years untouched. The plan was to chop it and do a hard tail build. I haven't done anything towards that yet, but I'm looking at how difficult that would be...

The forks are toast. Pitted and leaking and always have been. Tires are toast too. Dry rotted and bald. Since I have this "opportunity", what would be involved with replacing the forks with something from another bike? I assume I could find some more modern forks at a good price used.

I have a machine shop in my garage with a welder, lathe, and CNC mill, so I'm okay with fabricating parts. I know there's some specific angles in the steering geometry, so I assume I can't just get any used fork off ebay.

Thanks!

Title: Re: Replacing Forks
Post by verslagen1 on 09/28/23 at 20:33:28

There are many ways to do it, easiest being using a complete front end. Find a common sized set of head bearings and you're half way home.

Decide what wheel you want to use, axle size, how to set up the brake.

80's GS series bikes use a common head bearing and spindle length to the savage. As well as wheel size.

Title: Re: Replacing Forks
Post by Dave on 09/29/23 at 03:45:29

You should also try to find a front end with a similar offset of the steering stem and fork tubes. That distance is part of the geometry that establishes the "trail" in the front wheel.

I installed a set of yokes from a TM250 that had a lot less offset and it created a lot of trail. The bike steered like a truck as there was too much trail.

You should likely look at cruiser type front ends that have a front fork angle similar to the Savage - sport bikes and similar bikes with more vertical fork angles will likely not work well.

Title: Re: Replacing Forks
Post by Fast 650 on 09/29/23 at 17:11:26

Entire fork assembly (trees and forks as a set) from the 750/800 Intruder is supposed to be a direct swap and geometry is the same. The tube diameter is larger on those so you can't swap just the fork tubes by themselves, has to be the whole shebang.