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TE630 front forks modification/conversion

X

Xpat

Husqvarna
AA Class
Did anybody here tried to convert the TE630 travel length (I think 270 mm) back to the TE610 travel (I believe 300mm)? I have read somewhere (cannot remember where) that TE630/610 have the same forks - there is just spacer in 630 forks to make it shorter. Is this true? And if you've done it, can you please let us know how was the handling/stability affected and what components you need to change (different length springs?)?

My standard 630 suspension was set-up by a guy who knows what he is doing and today I took it for a ride in our local enduro loop of about 100km including single track in forest, rock sections, fast sections with whoops as well as dunes (well mine dumps). The rear shock was really working very well and I was able to really enjoy myself sliding the bike into the corners, which was very tricky with the stock hard set-up. The front though left me wanting a bit more. While it worked quite well on the whoops and never bottomed even when on occasion I got caught out by unexpected whoop, it was really harsh and on occasion bottomed on the hard short obstacles like rocks in the dirt road or just very short washouts. The bike also felt a bit "nose down" (I have big safari tank, but it was only half full), especially compared to TE610 riding with me, which was keeping its pose much better.

Would longer front travel with proper set-up and probably dumping compression adjustment added help with this? This is the last bit I need to iron out on this otherwise fantastic bike - I will appreciate your advice.
 
HuskyBrutha said:
You might wanna talk to BILLF.
He did this thread http://www.cafehusky.com/threads/project-te630-begins.17641/
where hed put a TE511 front end on his TE630......... seems like he runs a Husky shop as well:thinking:
Click to expand...
I had a look - it is very nice but I'm afraid it requires the whole front conversion including the triple clamps as it is 48mm fork, rather than standard 45mm. So I expect it to be very pricy.

But I might look into it if there is not other option. I believe you're from SA (as am I - the ride I described was in Maraisburg) - wouldn't you know about somebody who might have second hand front end from TE511/510 for reasonable price?

Ta
 
Xpat said:
I had a look - it is very nice but I'm afraid it requires the whole front conversion including the triple clamps as it is 48mm fork, rather than standard 45mm. So I expect it to be very pricy.

But I might look into it if there is not other option. I believe you're from SA (as am I - the ride I described was in Maraisburg) - wouldn't you know about somebody who might have second hand front end from TE511/510 for reasonable price?

Ta
Click to expand...
Ahh.........ok.........so you're not from the States, I thought you were that is why I recomended you talk to BillF.
I wasnt really suggesting you swap the entire front end out, not a bad idea, but a bit extreme I think.
I just thought that BillF may be able to give advice on the stock setup.

Me, I am pretty much a 630 noob with no 610 knowledge, so sorry I cant be of much help.
However as a local you must then be familiar with http://www.wilddog.za.net/forum/index.php ?

PM Blazes on that forum, he is a long time 610 owner and Husky afficionado and very knowledgeable on all things Husky to boot.
He also knows the name of a guy ( whoose name I forget ) in the workshop at Primrose Motorcycles who is very helpfull and who you may also want to speak to. Blazes is your starting point and he also knows of some Suspension specialists, and then of course there is always Runner (on the same forum )
Also on that forum is the Husqvarna section, http://www.wilddog.za.net/forum/index.php?board=123.0, where you can post there as there are a few 610 owners there as well.
 
Xpat said:
Did anybody here tried to convert the TE630 travel length (I think 270 mm) back to the TE610 travel (I believe 300mm)? I have read somewhere (cannot remember where) that TE630/610 have the same forks - there is just spacer in 630 forks to make it shorter. Is this true? And if you've done it, can you please let us know how was the handling/stability affected and what components you need to change (different length springs?)?

My standard 630 suspension was set-up by a guy who knows what he is doing and today I took it for a ride in our local enduro loop of about 100km including single track in forest, rock sections, fast sections with whoops as well as dunes (well mine dumps). The rear shock was really working very well and I was able to really enjoy myself sliding the bike into the corners, which was very tricky with the stock hard set-up. The front though left me wanting a bit more. While it worked quite well on the whoops and never bottomed even when on occasion I got caught out by unexpected whoop, it was really harsh and on occasion bottomed on the hard short obstacles like rocks in the dirt road or just very short washouts. The bike also felt a bit "nose down" (I have big safari tank, but it was only half full), especially compared to TE610 riding with me, which was keeping its pose much better.

Would longer front travel with proper set-up and probably dumping compression adjustment added help with this? This is the last bit I need to iron out on this otherwise fantastic bike - I will appreciate your advice.
Click to expand...
We are talking about a 1.2" difference of front suspension travel from an 09 TE610 vs. a 2011 TE630. I don't think slightly more fork travel will be noticed or fix your complaints. BTW, does the TE610 riding with you have a "big Safari tank" as well? I'm curious if you’re giving the TE610 an unfair advantage in this situation. In any event, there is also less ground clearance on the TE630 vs. the TE610, so I would be cautious of increasing the travel on the 630. You may be more prone to "casing it" on full compression jump landings. Perhaps you can go back to the guy who set up your suspension prior to this post and ask if he can adjust it further for you. Let us know how it goes.
 
What occurs to me is is the guy that set up your suspension does know what he is doing, he should be able to answer your questions. Did he change the stacks? How many miles/hours on the bike? The forks will soften up with use.
 
I'm typical user - I have no clue at all about internals of suspension, but I think I have reasonable good feel for what works for me or not. The 610 (completely standard without any suspension set-up) did not have Safari tank, however mine was only half full (i.e. about full standard tank) and as the petrol is lower (Safari reaches much lower than standard tank), I tend to believe that the tank should not make much difference (as it also reaches more to the front and therefore probably eliminated advantages of lower position). And the 610 definitely held its head up much better - 630 just did dive too much too quickly (before softening it was probably on par - but too harsh). That said, both of them suffered from quick hits - they just could not deflect rocks/edges properly. On longer rounded hits they worked both OK - except for the "head down" of 630.

My bike has about 7000 km on it and the suspension definitely softened up from the standard even before set-up. Blazes has recommended to me another guy who does his suspension so I'll try him once he is back from holidays and will report results. All I need is soft initial dumping to deflate quick hits with progressive hardening preventing bottoming out for "normal" riding - i.e. adventure riding and occasionally slow enduro trail (I have KTM 300 for proper enduro). I'm no motoX rider or racer - hence I'm not concerned about bike bottoming out on big jumps.
 
The main focus should be on your TE630 so eliminate the TE610 from this equation. It really doesn’t matter how the TE610 handles, what mods it has or what its fork travel limits are because it’s not your bike. The goal here is to get your bike’s front suspension to handle how you want it to.

I pretty much agree that a 1/2 full Safari fuel tank won't be a big difference vs. a full OEM tank on your TE630. The Safari tank for a TE630 has a 6.6 U.S. gallon fuel capacity and typical pump unleaded gas weighs a bit over 6 lbs per gallon. With the Safari tank full of fuel you will definitely feel your front end issues get worse.

Suspension bottoming can occur in countless situations while riding on a motorcycle. I used the term “full compression jump landings” as one example. I wasn’t implying that you raced motocross.

Good luck with your suspension tuning.
 
Hi Expat,

Just wondering how you fared with your forks? I've decided mine need modification and am going around in the same circles you already seem to have been in:D. Compression damping seems far to heavy (and of coarse unadjustable) and am thinking about this as a starting point. My main gripe is it is very hard to gain front end confidence in off camber or downhill breaking areas, as if the front end is too stiff. but i think maybe it is the damping being too stiff???
Hard to put in words really. Any info or modifications done would be interesting to hear.
 
630mick said:
Hi Expat,

Just wondering how you fared with your forks? I've decided mine need modification and am going around in the same circles you already seem to have been in:D. Compression damping seems far to heavy (and of coarse unadjustable) and am thinking about this as a starting point. My main gripe is it is very hard to gain front end confidence in off camber or downhill brieaking areas, as if the front end is too stiff. but i think maybe it is the damping being too stiff???
Hard to put in words really. Any info or modifications done would be interesting to hear.
Click to expand...

Oi

I had crash on my Tenere in December and was out of it for a while - so no change to my suspension yet. I have taken TE to a guy that Blazes recommended on Saturday and will see the result hopefully in about two weeks time (they are putting also steering damper on which I need to get delivered from US). They seemed positive in that they should be able to make the forks more progressive - i.e. soft in initial stroke so that it deflates sharp edges better and progressively stiffening so that it does not bottom out so easily (and hopefully keeps it head up better). They will also look into extending the travel to 300mm.

I will post about the results once done.
 
Yes this can and has been done. Reverting back to 610 type fork specs (1 inch longer travel) by removing the spacer and also adding compression adjusters. These guys have done it recently.
http://www.lt-racing.com/html/about_ltr.html

The one person I know who has done it doesn't have enough riding time after the upgrade yet to post a review. Be patient and you can read more about it soon I'm sure.

_
 
I had LTR go thru my front and rear suspension, and they put the travel back in the front forks. I haven't had a chance to try it out yet, but will soon. My Safari tank is in the garage and waiting to be installed, and it will be interesting to see how it works with the extra weight. I also had LTR put in compression dampers. I ride this weekend!
 
Kenneth Webb said:
I had LTR go thru my front and rear suspension, and they put the travel back in the front forks. I haven't had a chance to try it out yet, but will soon. My Safari tank is in the garage and waiting to be installed, and it will be interesting to see how it works with the extra weight. I also had LTR put in compression dampers. I ride this weekend!
Click to expand...

Please keep up posted. I want to do the same to my 630.
 
'Can't give specifics but they revalved all around, and softened the srings front and back to let me set my sag correctly. Stock springs were way too stiff for my 190" weight. The bike is set up for dual sport and to let the suspension soak up rocks, etc. Not a motocrosser! So far, on the roughest pavement I can find I'm using about 5/8 of the fork travel. The bike settles nicely when I'm on it. Report coming next week after my dual sport ride this weekend. Les at LTR was great to work with and listened carefully.
 
Kenneth Webb said:
'Can't give specifics but they revalved all around, and softened the srings front and back to let me set my sag correctly. Stock springs were way too stiff for my 190" weight. The bike is set up for dual sport and to let the suspension soak up rocks, etc. Not a motocrosser! So far, on the roughest pavement I can find I'm using about 5/8 of the fork travel. The bike settles nicely when I'm on it. Report coming next week after my dual sport ride this weekend. Les at LTR was great to work with and listened carefully.
Click to expand...

Any updates ?????

Sethro
 
I just had the compression adjusters installed a re-valve up front. Didn't have any desire to increase the fork travel or change spring rates. Just returned from a weekend trip that totaled 450 miles of very mixed terrain.
What an improvement! Very happy and will move on to sorting out the rear shortly.
 
How did you get compression adjusters installed? Are they from another bike or easy to install? I'm new to this suspension stuff on bikes and wish to mod my front forks to be able to adjust compression aswell.
 
Rallystanza said:
How did you get compression adjusters installed? Are they from another bike or easy to install? I'm new to this suspension stuff on bikes and wish to mod my front forks to be able to adjust compression aswell.
Click to expand...

The adjusters are a Marzocchi part. Simple install, but I also had a re-valve performed to smooth things out. Lot's of bang for the buck.
 
Where can one find those "simple install" instructions for a "do it yourself" effort?
 
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