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Old 04-02-2012, 07:19 AM   #1
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crf100-change front for disc brakes?

ok, so this weekend I got to ride Steve's bike for a few laps and I really like the disc brake on his bike... having a brake that works like that can change the whole approach to cornering... i did not really push it since it was not my bike, but i liked the difference in the braking...(he was riding mine testing the jet change in the carb)...
those of you who have made that change on your bike, what front end did you use, how much work was it, and if you did it again would you use the same front end?
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Old 04-02-2012, 07:47 AM   #2
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kx80 or cr80 front end, are probably the most common.
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Old 04-02-2012, 07:57 AM   #3
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Quote:
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kx80 or cr80 front end, are probably the most common.
which one did you use?
I am thinking hard about it, cause if I do the big bore kit later, I will really want a better braking system.
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Old 04-02-2012, 08:12 AM   #4
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I've got a set of KX80 forks but they aren't on yet. There is a cheap yz85 for sale on craigslist (austin I think) that would all be a candidate for a swap.
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Old 04-02-2012, 08:27 AM   #5
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I did a CR80 front swap, still conventional forks but worked fine.

I am a cheap old fart, here is what I did to swap:

Parts needed:
1. Forks and triple's from CR80 (the lower is steel and upper aluminum)
2. Extra Triple from CRF/XR 100/80
3. MIG Welder
4. Angle grinder
5. Ball peen hammer and drift

ON the extra CRF triple, grind the factory weld from the bottom of the steering stem until you can clearly see the seem all the way around. Then using the drift and hammer, punch the stem out of the lower and set aside.

Repeat on the CR front end. You will notice the CR steering stem is larger in diameter than the XR, dont sweat it.

I used my vise to clamp the XR stem with the bottom up and put the CR lower over the stem. Adjust it so the stem is flush with the bottom of the clamp and centered as close as you can get (I just eyed it) Fire up the MIG< I used .035 wire with 75/25 gas, tack the stem on three sides (small tacks) take it out of the vise and check with a square to make sure you are straight. If not you may need to grind and repeat until it is straight in relation to the lower. When you have it right, burn it in with a good solid bead. (welding skills are necessary to do this, if you can't weld, you can send me the parts and I can do this for a small fee ). I thought about having a shim made to fill the gap and then weld it, but the machine shops around here wanted a hundred dollars to make them for the top and bottom. I also thought about welding from the top of the lower triple and filling the gap that way, but decided against having to grind the weld to make the bearing race slide all the way down.

With the new stem in the lower, transfer all of the bearings and races from the XR/CRF front end and install the triple on the XR frame. The upper will have a slight gap around the stem as the lower did, and there are two ways to fix this. You can have a shim made that fills the gap, or you can line it up and clamp it down and go. I did the latter, and ran two full season's with TMPG and never had an issue.

That is about it. It took me about an hour to do the whole swap. Sorry I don't have any pictures. If you have any questions I will try to answer them as best I can. THe biggest draw back of this swap is the travel of the CR forks, they are about 4 inches longer than the XR forks and have about 8 inches of travel, you will want to shorten the length so you dont throw your geometry out of whack. Nothing too drastic, but after an hour on the bike you will be really tired from the extra effort required to shove the bars around. I cannot remember how we limited the fork travel, and it will vary depending on the donor bike. We put new seals and heavy oil in them and they handled pretty good considering the amount of weight they carried around! Have fun.

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Old 04-02-2012, 01:05 PM   #6
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sounds easy enough...
now you guys that used other front ends, what did you do...
right now i am seeing some kx front end possibilities out there but nothing in the cr line... but it is early yet, and this is something I may not do until the end of this season...
I know that after Steve road my bike he was glad to get back on his for the brakes...
he forgot for a moment that he was on mine and waited too late to brake for turn one (too late for my brakes) and took a tour of the grass, made it look cool though, he just bypassed turn two and rode over to the entry of turn 3 and resumed...
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Old 04-02-2012, 01:46 PM   #7
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Quote:
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sounds easy enough...
now you guys that used other front ends, what did you do...
right now i am seeing some kx front end possibilities out there but nothing in the cr line... but it is early yet, and this is something I may not do until the end of this season...
I know that after Steve road my bike he was glad to get back on his for the brakes...
he forgot for a moment that he was on mine and waited too late to brake for turn one (too late for my brakes) and took a tour of the grass, made it look cool though, he just bypassed turn two and rode over to the entry of turn 3 and resumed...
I think it the same thing as the kx85 forks too just have the stem removed out of your tripe and put in the cr triple

search www.thumpertalk.com tons of info on the xr/crf100
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Old 04-02-2012, 02:11 PM   #8
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haha...sorry about that little "detour". That was a real eye opener how much difference there is - you probably need another 15-20 feet of braking to get slowed down into turn 1 with drums. I'd imagine they'd fade pretty bad in an endurance race too.
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Old 04-02-2012, 02:16 PM   #9
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Old 04-02-2012, 02:35 PM   #10
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Kib, that is nice,,,, with that it is just take it off the kx and put it on the crf...done.

and that rear link looks like it takes a lot of work out of having to adjust for fork travel too...
hmm.. now this may be something to play with...
any of you guys actually tried this?
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Old 04-02-2012, 02:40 PM   #11
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I've seen guys also pull the xr100 motor and fit it into a cr80 rolling chassis. Gives you all of the braking/ handling/ etc. of the cr80 with the motor of the xr100.
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Old 04-02-2012, 02:44 PM   #12
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I've seen guys also pull the xr100 motor and fit it into a cr80 rolling chassis. Gives you all of the braking/ handling/ etc. of the cr80 with the motor of the xr100.
yep that is what dennie did, he modded the suspension too but I have not talked to him about what mods he did.
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Old 04-02-2012, 03:30 PM   #13
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Quote:
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Kib, that is nice,,,, with that it is just take it off the kx and put it on the crf...done.

and that rear link looks like it takes a lot of work out of having to adjust for fork travel too...
hmm.. now this may be something to play with...
any of you guys actually tried this?

idk about that rear linkage....its not all its cracked up to be, it does raise the rear but you then have other clearance issues to deal with not to mention your shock choices for the xr/crf100 SUCK including the NONadjustable works shock that so many rave about

there is a new rear shock that appears to have potincial for the xr/crf100 but I dont know anyone that has tried it http://www.minimobracing.com/store/X...duct_info.html


go with the cr85 chassis
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Old 04-03-2012, 12:30 PM   #14
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how old a cr85 chassis will work... before they had inverted forks, would that be any improvement...
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Old 04-03-2012, 02:27 PM   #15
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well, I am getting a rolling chassis from tomlstd.. it is an older one and i will check it out and see what I can use and what I can not... the front end is an older cr85 front end (not inverted) with disc brakes, and it has an aluminum swing arm with disc brakes that is supposed to be able to bolt onto the crf100.. but if it does not work out no big deal... got it from tom for a song and I can't sing...tom thinks the frame itself was an old xl125, but he is not sure...
so it is something to tinker with...
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Old 04-03-2012, 02:37 PM   #16
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I am thinking old CR forks (non inverted style) slide right into xr100 triples. Do you know what year it is?
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Old 04-03-2012, 02:51 PM   #17
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no, he does not know the year.. and the parts are supposed to be "bolt on" to a crf100 frame...Tom said the key word here is "supposed to be" as he has not tried it..
he knows the swing arm and rear disc brake as well as the tripple, forks, front disc and hub and wheels are off an old crf, but not sure what the frame is exactly, again, thinks is was an xl125 but not sure...
any way it is cheap enough that if it does not work out, it will the give the grandson something to play with taking apart....
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Old 04-03-2012, 02:54 PM   #18
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Cool deal. I am sure if you planned a wrenching weeknd the tmgp guys would help put her together.
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Old 04-03-2012, 03:22 PM   #19
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well, i am supposed to pick it up tomorrow...
not sure when I will have the first opportunity to fool with it...
then I will decide if I am going to pull the parts off the rolling chassis and put them on my frame, or if I am going to pull the motor and put it in the rolling chassis..
or if it all goes in the dumpster....
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Old 04-03-2012, 10:36 PM   #20
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I've got an extra XR100 frame somewhere if you want to just slap the fork and swingarm on real quick and see how stuff fits.
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