1978 TT500 fork change

Easy as Pie Front End Swap: The complete ’73-74 TX750 factory front end will slide directly into stock TT500 triple clamps with a 19” front wheel, disc brake and all the factory spacers, etc. It’s a part-for-part swap on the TT frame with even the same bearings! No shims, no fabrication of spacers, just a bolt-on 19” front wheel with a disc brake. So cool, so complete, so easy.

There are several forks that will fit your stock 36mm XT/TT500 triple trees: All Suzuki PE/RS models except ‘82-84 175's have 36mm forks. Any XJ550, XJ650, XJ750 Maxi, even a KZ650 or KZ750 will fit. I'm using a XV535 Virago fork with a XS750 mag wheel for the front. Whichever fork you use will have to use the axle and you’ll need to make a spacer for whatever wheel you use. Most Yamaha axles for these street bikes are 11/16” or 17mm. Keep that in mind with your wheel choice. The KX250 triple tree requires a smaller diameter lower bearing pressed on the stem.

The late 80's FZ600 forks will slide in the stock clamps at 36mm with 5.1" of travel and came with a twin set of brake discs (Remove one for TT or convert it to a rear disc). The early ‘90s FZR600 forks with 4.8" of travel will work if you bore the stock clamps to 38mm (37.96mm). They have the better brake set up. Both are a bit soft for TT racing IMO. Progressive rate suspension springs stiffen them up but then they are a bit too stiff for flat track (IMO). I believe the YX600 used the same basic fork as the FZR600 but had 5.1" of travel and a bit shorter upper tube set. The 38mm forks have demonstrably better feel compared to the 36mm (again IMO) and are lighter too. Axle bolt was a junkyard find.

Most late 70's early 80's SUZUKI or YAMAHA front forks will fit. They are all KAYABA's and use the same size bearings but have different length steering tubes. I re-machined mine to fit but you can use spacers. Most internal parts will interchange. YAMAHA triple clamps combined with SUZUKI fork legs gives much better turning and stability. Try early 80's Honda XR250 23lb/in springs.

Most Yamaha front ends from the same time frame will fit. YZ/IT front ends have the same size steering shaft so will fit the standard ball bearings. There are kits to convert them to tapered rollers, well worth the change. Check the length of the steering stem, some YZ/IT are shorter. I used a longer Suzuki one and shortened it.

I found the front will stick better if you use SUZUKI fork legs with Yamaha triple clamps as they have less offset than the YAMAHA and give a little more trail. If you are keen then steepen the steering head angle. Mine runs 27 degrees on the steering head and handles great.

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