KYB Conversion WP AER-48 (2016.5 - 2020) (Short KYB Cartridge)

Your Price: $250.00

Part Number: WP16KKIT-S

Availability: In Stock. Free Shipping.

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Description

KYB Conversion '2016.5 - 2020 WP AER-48 (Short KYB Cartridge)

KYB Cartridges and springs are not included

Installation requires fork lug removal
This kit will allow you to install KYB (Yamaha SSS) springs and cartridges in your 48mm WP AER-48 forks on 2016.5 - 2020 full size motocross models as well as off-road models equipped with pneumatic spring forks. This alternative kit allows use of the older Yamaha and Honda fork cartridges which are often available at a lower price than the late model Yamaha and Kawasaki parts. These early KYB cartridges are about 10mm shorter than the current models, so this kit will compensate to preserve your existing chassis geometry.

KYB fork cartridges and springs can be sourced from the motorcycles listed below.
Most of these shorter version KYB cartridges have a 55.6mm flange on the top cap that must be reduced to 53.6mm diameter to clear your top triple clamp.
Please see the Technical Information page. Dialed Mfg can perform the modification free of charge if you cover shipping. [email protected]

For 2016.5 - 2020 KTM and Husqvarna:

2008 - 2009 YZ450F
2008 - 2013 YZ250F
2008 - 2023 YZ250 & YZ125
2009 - 2012 CRF450R

Detailed installation instructions will be available soon for these AER-48 (2016.5 - 2020) KYB conversion kits.
A brief installation process is listed below:

1) Remove the AER-48 forks from the motorcycle by removing the front wheel, front brake caliper, fork guards and pulling the forks out of the triple clamps.

2) Disassemble each AER-48 fork as if you were completing a seal and bushing replacement service.

3) While holding each 48mm steel lower fork stanchion tube in a soft vise block or other soft fixture, remove the fork lug by un-threading it. The threads are standard right-hand threads. To aid fork lug removal, heat the fork lug to soften the thread-locking compound installed at the WP factory. Heating can be done with a propane, MAPP or butane torch. Approximately 280°F to 300°F is hot enough. The temperature of the aluminum lug should never exceed 320°F at any time.

4) After the parts cool to room temperature, remove the gray oil lock cup and the blue puck from their associated fork lugs. Sometimes these parts require being driven out from the bottom of the fork lug through the rebound adjuster port. The only thing holding them in place is a yellow 48mm o-ring that sits in a groove within the fork lug. New black o-rings are included with each kit that match the size of the OE yellow rings.

5) Thoroughly clean the threads in the fork lugs and on the 48mm stanchion tubes to remove the remaining OE thread-locking compound.

6) Apply a small amount of suspension grease or white lithium grease to the new 48mm black o-rings included in the kit and install them in the grooves below the threads in each fork lug.

7) Apply a reasonable amount of medium-strength thread-locker (blue LockTite) to the threads on each 48mm fork stanchion tube.

8) Place each of the Dialed Manufacturing KYB conversion oil-lock adapters into the threaded ends of the 48mm fork stanchion tubes so that the oil-lock cups and pring-seats are inside the stanchions. Then thread the fork lugs onto the stanchion tubes as far as possible by hand.

9) While holding each 48mm fork stanchion tube in a soft vise block or other soft fixture, tighten the fork lug onto the tube.

10) Clean and inspect the lower stanchion assemblies before re-assembling the fork legs with fresh seals and bushings per the KTM / WP service instructions.

11) Install the KYB coil springs, spring perches and damper cartridges into each fork leg using the procedures recommended by the manufacturer of the donor forks (Yamaha / Kawasaki / Honda / KYB) using the rebound adjuster assembly included with the Dialed Manufacturing conversion kit.