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RE Himalayan front suspension on Duke 200

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  • #1

    RE Himalayan front suspension on Duke 200

    Oh fellow xBhpians, I come here to seek wisdom. I wish to convert my Duke 200 into Duke 200 Adventurer, which entails better long travel suspension, wire spoke wheels and dual sport tyres. Before I set off spending my credits and trying to figure stuff on the way, I wish to know what grand adventures or headaches will I have to face.

    First objective is to use RE Himalayan front forks and front wheel on my Duke 200.

    How can I do that, what problems can I run into, what would i need to make it possible?

    Can I bolt on the Himalayan triple tree onto my Duke 200 without any modifications to frame stem?

    Please guys and gals, contribute your wisdom and lets see if we can create Duke 200 adventurer in a tight budget?
    Last edited by xBhp; 05-25-2019, 07:00 PM.
    Tags: None
  • #2
    Re: RE Himalayan front suspension on Duke 200

    Thread approved.

    Comment

    • #3
      Re: RE Himalayan front suspension on Duke 200

      Originally posted by Yogesh_kgp View Post
      Oh fellow xBhpians, I come here to seek wisdom. I wish to convert my Duke 200 into Duke 200 Adventurer, which entails better long travel suspension, wire spoke wheels and dual sport tyres. Before I set off spending my credits and trying to figure stuff on the way, I wish to know what grand adventures or headaches will I have to face.

      First objective is to use RE Himalayan front forks and front wheel on my Duke 200.

      How can I do that, what problems can I run into, what would i need to make it possible?

      Can I bolt on the Himalayan triple tree onto my Duke 200 without any modifications to frame stem?

      Please guys and gals, contribute your wisdom and lets see if we can create Duke 200 adventurer in a tight budget?
      you will need to replace the triple clamp.
      Or you could just replace the fork oil of your existing fork and with a lighter one and make it soft.
      Read the Thread below:
      Motorcycle Fork Oils - xBhp.com : The Global Indian Biking Community
      https://www.xbhp.com/talkies/universal-threads/28554-motorcycle-fork-oils.html
      The gold mine of all the topics which are frequently discussed..
      Hero Honda Splendor (June 2001- Present)
      Yamaha YZF R3 (Jan 2016 - Present)
      TVS Scooty Zest 110 (Oct 2017 - Apr 2018)
      TVS Ntorq 125 (May 2018 - Apr 2019)
      KTM Duke 125 (Apr 2019 - Dec 2019)

      Comment

      • #4
        Re: RE Himalayan front suspension on Duke 200

        Originally posted by Gollum View Post
        you will need to replace the triple clamp.
        Or you could just replace the fork oil of your existing fork and with a lighter one and make it soft.
        Read the Thread below:
        https://www.xbhp.com/talkies/univers...fork-oils.html
        Thank you for this info. This is the most easiest way to change my suspension stiffness, however i am skeptical that it would increase my suspension travel. Thinking emoji.

        Comment

        • #5
          Re: RE Himalayan front suspension on Duke 200

          Originally posted by Yogesh_kgp View Post
          Thank you for this info. This is the most easiest way to change my suspension stiffness, however i am skeptical that it would increase my suspension travel. Thinking emoji.
          Just wait for the 390 Adventure duke. You can then just buy its forks and install them on your bike. I might do that too but then again, I might sell my duke by then.
          Hero Honda Splendor (June 2001- Present)
          Yamaha YZF R3 (Jan 2016 - Present)
          TVS Scooty Zest 110 (Oct 2017 - Apr 2018)
          TVS Ntorq 125 (May 2018 - Apr 2019)
          KTM Duke 125 (Apr 2019 - Dec 2019)

          Comment

          • #6
            Re: RE Himalayan front suspension on Duke 200

            Originally posted by Gollum View Post
            Just wait for the 390 Adventure duke. You can then just buy its forks and install them on your bike. I might do that too but then again, I might sell my duke by then.
            Similar thought my friend. It was just my curiosity to try and mod my ride, so i can take to trails without having my back broken in the process.

            Comment

            • #7
              Re: RE Himalayan front suspension on Duke 200

              Originally posted by Yogesh_kgp View Post
              Similar thought my friend. It was just my curiosity to try and mod my ride, so i can take to trails without having my back broken in the process.
              Duke 200 has 148mm front fork travel.
              But in reality it is less than 80mm - which is equivalent to a Hero Splendor.

              I was reading up on this and while researching I found that the spring that is probably installed on Duke is a Veriable stiffness spring.
              Meaning at one side the spring has more coils and at one end there are lesser coils. Something like below.

              o||///// / / / / / / /||o

              If the whole spring was of the same coils length it would provide a linear stiffness instead of being soft at one level and stiff at another.

              o||//////////////////||o
              Hero Honda Splendor (June 2001- Present)
              Yamaha YZF R3 (Jan 2016 - Present)
              TVS Scooty Zest 110 (Oct 2017 - Apr 2018)
              TVS Ntorq 125 (May 2018 - Apr 2019)
              KTM Duke 125 (Apr 2019 - Dec 2019)

              Comment

              • #8
                Re: RE Himalayan front suspension on Duke 200

                Originally posted by Gollum View Post
                Duke 200 has 148mm front fork travel.
                But in reality it is less than 80mm - which is equivalent to a Hero Splendor.

                I was reading up on this and while researching I found that the spring that is probably installed on Duke is a Veriable stiffness spring.
                Meaning at one side the spring has more coils and at one end there are lesser coils. Something like below.

                o||///// / / / / / / /||o

                If the whole spring was of the same coils length it would provide a linear stiffness instead of being soft at one level and stiff at another.

                o||//////////////////||o
                Nice bit of info. Even i was awestruck by the theoretical 150mm of travel, your findings explains my conundrum. Changing the fork springs is one option, dont know if I'm ready to face the problems it throws.
                Another option i stumbled upon. My ktm mechanic has confirmed that pulsars entire fork setup with t stem can be installed on duke without any mods. And good thing is fork dia is 37mm which is same as Xpulse 200's fork dia. So.....
                Last edited by Yogesh_kgp; 06-07-2019, 07:32 PM.

                Comment

                • #9
                  Re: RE Himalayan front suspension on Duke 200

                  Originally posted by Yogesh_kgp View Post
                  Nice bit of info. Even i was awestruck by the theoretical 150mm of travel, your findings explains my conundrum. Changing the fork springs is one option, dont know if I'm ready to face the problems it throws.
                  Another option i stumbled upon. My ktm mechanic has confirmed that pulsars entire fork setup with t stem can be installed on duke without any mods. And good thing is fork dia is 37mm which is same as Xpulse 200's fork dia. So.....
                  what I want to know is if the springs can be replaced?
                  And which bike springs fit
                  Hero Honda Splendor (June 2001- Present)
                  Yamaha YZF R3 (Jan 2016 - Present)
                  TVS Scooty Zest 110 (Oct 2017 - Apr 2018)
                  TVS Ntorq 125 (May 2018 - Apr 2019)
                  KTM Duke 125 (Apr 2019 - Dec 2019)

                  Comment

                  • #10
                    Re: RE Himalayan front suspension on Duke 200

                    Some guys on Duke 390 forums have replaced their internal spring for a much stiffer one from RC 390. They even played around with spacers to make their rides stiffer and track ready.
                    We can decrease the fork oil from 450ml to 400ml to make it soft. What i found is stock spring rate for D390 is 0.62kg/mm and are 320mm long ( dont quote me on this, i might be off by a blond one). Its my guess that it might be same for D200. However, i dunno the dia of the springs so as to find a similar diametre spring.

                    Comment

                    • #11
                      Re: RE Himalayan front suspension on Duke 200

                      Originally posted by Yogesh_kgp View Post
                      We can decrease the fork oil from 450ml to 400ml to make it soft.
                      I think instead of filling less suspension fluid, one should rather change the grade, lower = softer & higher = stiffer.
                      Last edited by Zapps; 06-09-2019, 10:52 AM.

                      Comment

                      • #12
                        Re: RE Himalayan front suspension on Duke 200

                        I would rather add lesser suspension fluid and that too if lower weight/viscosity.
                        Today i tried to push the front suspension on my Duke and it would not go down at all. Did the same with my R3 went down as if it was waiting for me to push it down lol.
                        Hero Honda Splendor (June 2001- Present)
                        Yamaha YZF R3 (Jan 2016 - Present)
                        TVS Scooty Zest 110 (Oct 2017 - Apr 2018)
                        TVS Ntorq 125 (May 2018 - Apr 2019)
                        KTM Duke 125 (Apr 2019 - Dec 2019)

                        Comment

                        • #13
                          Re: RE Himalayan front suspension on Duke 200

                          Originally posted by Gollum View Post
                          I would rather add lesser suspension fluid and that too if lower weight/viscosity.
                          Today i tried to push the front suspension on my Duke and it would not go down at all. Did the same with my R3 went down as if it was waiting for me to push it down lol.
                          I did the rubber band test and measure the entire fork travel. Without rider Travel is 100mm. Once I'm on it all i can get is 80mm or less and that too under hard braking.

                          Comment

                          • #14
                            Re: RE Himalayan front suspension on Duke 200

                            Changing to lower weight oil and using less of it can make suspension soft, however i have my doubts that we would get any extra suspension travel than 80mm.

                            After watching a ton of youtube on how to take apart ktm forks, i have successfully laser eyeballed the spring dia to be in between 25-37mm. In my mind fz250 uses 41mm forks and is much softer than ktm. There is a possibility that we can use its internal springs.

                            What do you think?

                            Comment

                            • #15
                              Re: RE Himalayan front suspension on Duke 200

                              Originally posted by Yogesh_kgp View Post
                              Changing to lower weight oil and using less of it can make suspension soft, however i have my doubts that we would get any extra suspension travel than 80mm.

                              After watching a ton of youtube on how to take apart ktm forks, i have successfully laser eyeballed the spring dia to be in between 25-37mm. In my mind fz250 uses 41mm forks and is much softer than ktm. There is a possibility that we can use its internal springs.

                              What do you think?
                              It all remains to be tested. I would rather dismantle the KTM suspension first and then try to get a similar spring.
                              A longer spring will definitely help as it will reduce the "sag" and thus improving the overall suspension travel.
                              I believe getting suspension components from Bajaj and Yamaha might be easy.

                              As per the link below the forks are 43mm on KTM which is the same on new Dominar400
                              KTM: https://www.ktm.com/in/naked/125-duke/Overview
                              Dominar: https://www.bajajauto.com/motor-bike...specifications

                              On the otherhand, CB300r has 41mm forks
                              Honda: https://www.hondabigwing.in/Content/pdf/CB300R.pdf

                              Also I found the reference for springs used on KTM 125
                              Hero Honda Splendor (June 2001- Present)
                              Yamaha YZF R3 (Jan 2016 - Present)
                              TVS Scooty Zest 110 (Oct 2017 - Apr 2018)
                              TVS Ntorq 125 (May 2018 - Apr 2019)
                              KTM Duke 125 (Apr 2019 - Dec 2019)

                              Comment

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