Tenere 700: Rally Raid Tenere 700 Adventure 35 mm Open Cartridge Fork Kit (5.6/6.0 Nm Springs + 90/95 Nm Rear Springs) + Revised Compression Piston - Rally Raid & K-Tech Shock Springs Differences - T700 Hydraulic Preload Adjustment (HPA) & Load Compensation - SKS Fork Seals - Tusk Fork Oil Level Tool & Fork Seal Driver - TR Deisel Yamaha Steering Head Ring Nut Wrench - Yamaha Engine Alignment Tool #90890-11097-00

 Rally Raid T7 Adventure 35 mm Open Cartridge Fork Kit

The Rally Raid Tenere 700 Adventure 35 mm open cartridge fork kit was developed in conjunction with Tractive Suspensions in the Netherlands and offers a substantial increase in performance & adjustability over the oem forks.

• fully adjustable for spring preload with rebound & compression damping in separate forks with top mounted adjusters
• 35mm piston for improved oil flow, damping performance, feel & response time
• supplied with linear fork springs (5.6 Nm or 0.57 kg/mm, 6.0 Nm or 0.61 kg/mm, 6.4 Nm or  0.65 kg/mm) to match the rider weight
• hard anodized aluminum components to give optimum performance, reduce friction & make service simpler & less frequent
• Rally Raid designed hydraulic end stop (PDS) avoids mechanical impact on the forks
• includes adjustable fork preload caps (11mm range) & spanner + additional plastic spacers for up to another 12mm of preload range.

It has the same travel as the OEM fork, but with a much higher performance & adjustability, utilizing a 35mm diameter piston (the largest size on the market), rather than the OEM 20mm diameter piston, this allows for much larger shims, giving 270% more surface area & a much more progressive shim feeling due to increased oil flow. 

NOTE Aug 2021: Responding to rider feedback & to improve fork compliance Rally Raid is developing a revised compression piston assembly (gen 2) for release in early 2022 designed to increase compression oil flow by about 30% making initial movement more plush & revised recommended damping settings substantially softer, in an effort to improve & broaden the already dynamic operating range. They will send it to me when the production version becomes available...will update with installation details & ride evaluation comparison upon arrival...see install below Dec 2023.

This is a complete bolt in kit including Motorex 5w fork oil...I tried both 5.6 Nm & 6.0 Nm springs...oem = 0.60 kg/mm or 6.1 Nm (as per Rally Raid).

 

Significant Design, Function & Size Differences Between the Rally Raid & OEM Fork Cartridges

The OEM Spring is 10mm Shorter

Installation

Rally Raid provides concise instructions on their website, click Support & Fitting tab

+ comprehensive installation video by Everything Tenere below

Installed the rebound fork on the right then discovered a little hick-up that I hadn't noticed when they arrived - the compression cap o-ring was missing, but decided to go ahead & install anyways as it can easily be installed when it arrives. You can really feel the PDS stiffen up in the last 10-12 mm of stroke! It took about 2x as long to get the air purged on the compression side. The Rally Raid 6.0 Nm springs are 10 mm longer (435 mm) & feel stiffer than the oem, despite similar spring ratings, perhaps a result of having more inherent preload with the longer length. The kit uses approximately 450 mm/leg Motorex 5w Racing Fork Oil & set the recommended 120 mm air gap (100 mm recommended for harder off road riding), compression damping -6 of 24 clicks & rebound -4 of 20 clicks, which feels significantly stiffer & more damped than the oem (subsequently revised softer after release of the gen 2 compression piston assembly in 2022), no added spacers (included) to the pre-load adjustable caps (added +1 click of preload) & the top of the fork tubes 7 mm above the triple clamp.  

Tech TIP: Be careful & thorough with fork alignment & of the right caliper/rotor gap, which is impacted by the floating right axle & that the fender is not introducing torsional loads to the forks, or you could end up with stiff forks in the initial travel, which happened to me. See my blog post on fork alignment & right caliper/rotor gap fitment issues via this link.  

Just a quick shout out to John Mitchinson @ Rally Raid who called the next morning after I emailed about the missing fork cap o-ring  & my stiff forks issue, who offered a few fork alignment solutions to try (see below) & will include softer 5.6 Nm springs for me to compare to the 6.0 Nm springs + a 95 Nm rear shock spring to compare to the 90 Nm, along with the replacement cap & fork slider o-rings + will send the newly developed compression piston assembly designed to increase oil flow & fork compliance when it becomes available in early 2022...outstanding customer service. 👍

John has found fork miss-alignment to be a common cause of excess fork stiffness...they have also experienced the issue with the right caliper & rotor not lining up & also discovered that some shops/owners hammer the axle to get it in & mushroom the end (he turns the end of the axle down on a lathe to fix that issue). His technique for aligning the Tenere 700 forks is to remove the right caliper & insert something approx 6 mm (thickness of rotor) in between the pads of the dangling caliper...then hand insert the axle & tighten & apply & hold the brakes & bounce the forks & tighten the pinch bolts...then re-attach the caliper & check the fork movement & caliper/rotor clearance. 

Thanks to Marcus Palmehorn @ Everything Tenere & his detailed Rally Raid Open 35 mm Cartridge Fork Kit install video (see below) where he recommends loosening all the fender bolts (which contributed to my particular issue) + the steering stem nut (did not do this, but it did need retorqued as it had loosened slightly in 4k km of use) in addition to the axle pinch bolts. 

Initial Observations Rally Raid 6.0 Nm Fork Springs & OEM Shock/Spring (correct Rider Sag unobtainable)

Each change was evaluated in progression to ensure a reasonable sense of what impact each had: 1st with 6.0 Nm fork spring & oem rear shock/spring, then changing to 5.6 Nm fork springs, then RR 90 Nm shock spring & correct rear sag, then 95 Nm shock spring & revalved oem shock, then 6.0 Nm fork springs & finally 90 Nm shock spring. Correct front sag was used for all fork set ups, correct rear sag could only be set with the Rally Raid 90 & 95 Nm shock springs. For context regarding my observations I have 30 yrs predominantly road bike riding/touring experience with the last 8 being 60-70% street/30-40% FSR adventure touring riding.

Wow, what a difference the Rally Raid 35mm Open Cartridge Fork Kit makes...the improvements in damping, tactile feedback & poise over a wider range of terrain & riding styles + effective & large range of adjustability cannot be overstated! Outside of the initial fork travel stiffness I experienced due to fork & fender alignment issues during reassembly, which was mostly corrected, it is fair to state that it is transformative to the handling & feel of the bike. So much so that deficiencies with the oem rear shock will be begging for attention...correct shock spring, sag & revalve/piston upgrade will narrow the performance & front to rear balance disparity gap sufficiently for most. For more aggressive, higher skilled riders & those willing to part with the money Rally Raid & others offer high end shocks with high & low speed circuits. See MAD TV video below for detailed comparison review of 3 Tenere 700s with correct springs/sag & 3 different suspension set ups over a variety of challenging Australian back country roads meant to expose their strengths & weaknesses: 1 with revalved oem forks & shock, 1 with K-Tech springs & piston kits in the oem forks & shock & 1 with Rally Raid 35 mm Open Cartridge Fork Kit & Adventure Shock. 

The front end now retains a well damped, sure footed stance that urges you to seek out bumps, irregularities, holes & woops of ever increasing sizes...the bigger & faster the hit the more that the Rally Raid Fork Kit distinguishes & sets itself apart from the oem units, particularly with high g scenarios where they absorb them with progressive full travel minus the harsh bottoming of the oem forks. Overall they provide a firmer, much improved & damped ride that is appreciated everywhere, but in particular displaying their prowess off-road & when pushed hard...more commensurate with the Tenere 700 Adventure Bike/big Dual Sport mission vs the oem units (which to be fair aren't bad, just built to a price point with a lower & more limited performance envelope). 

Rally Raid's name may provide a clue as to the fork kit's target audience & state of tune, which based on other reviews & my experience gravitates towards off-road use & a design intended to cover a wide range of rider/load weights & riding type up to aggressive off-road with high g loads on a 205+ kg or 452+ lb bike without the need for rider/weight specific valving (speculation on my part). As such I found the tuning too stiff when set to the recommended damping settings of 6 clicks out from fully clockwise (24 clicks total) for compression & of 4 clicks out from fully clockwise (20 clicks total) for rebound. I settled in with -24 of 24 clicks compression & -16 of 20 clicks rebound for my typically 70/30 road biased solo riding without luggage, which improved compliance substantially. Rally Raid has subsequently revised softer recommended damping settings with the release of the gen 2 compression piston assembly in 2022. All in all, it is an impressive & unique kit with a very wide range of adjustment & performance envelope! 

If there is a nitpick, & this becomes highly personal, dependent upon many factors & may not be much of an issue to dirt & aggressive riders, I found that the fork kit gravitates to a livelier, tactile feel on initial travel that not fully absorbs smaller surface irregularities, particularly at lower speeds & while the fork kit provides dramatic & impressive performance over the oem forks across the board, just don't expect touring bike suppleness/isolation from the gen 1 fork kit. Perhaps that was an unrealistic expectation on a bike of this weight designed for Adventure touring, but it appears that Rally Raid has targeted it as an area for seeking improvement after just 1 year of production of the fork kit. I will report on the >early 2022 gen 2 revised compression piston & valve assembly that is intended to broaden the already wide dynamic operating range with improved initial travel compliance when it arrives.

 Rally Raid 6.0 Nm Fork Springs & RR 90 Nm Shock Spring (with correct Rider Sag) 

Things came into focus once the correct springs & sag at both ends was set making the bike more balanced with the front & rear more in synch, however, the oem rear shock will need revalved in an effort to catch up to the Rally Raid front end, particularly for rebound...a balanced chassis is paramount to so many desirable dynamics. In particular, harshness of the rear shock has diminished noticeably simply because it sits higher in it's stroke, dramatically improving effectiveness...even the front feels a little more compliant.  You can hammer off shifts with WOT while heeled over & the chassis just remains level & planted, no head shake or wandering. You can tell that the front is now more weighted & planted as the Mitas E-10 now produces a little howl when leaned over compared to with the much softer oem rear spring & inability to set correct sag. It is surprising how much smoother both ends feel, particularly on sharp edged hits, while still being firmly suspended. Standing & bouncing the bike as hard as I can now only uses up about 2/3 of the full travel & both ends now move in unison, in stark contrast to the oem set up which had the rear out of synch with the front & using most of its travel fairly easily. 

Rally Raid 5.6 Nm fork springs, the missing fork cap & leg o-rings from the original order, more stickers + a 95 Nm rear spring  to compare to the 90 Nm originally ordered. 

 Rally Raid 5.6 Nm Fork Springs & 90 Nm Shock Spring (with correct Rider Sag) 

Click here for my blog post on OEM Spring Rates, Sag Measurements, Suspension Settings & Weights

The softer 5.6 Nm springs improve on initial travel compliance & small irregularity response.  It now absorbs most road irregularities & sharp edged surfaces with a well damped, yet tactile suppleness the oem suspension could only dream of, with a progressive firmness that seems to never run out of suspension travel. The trade off vs the firmer 6.0 Nm springs, that didn't quite allow the fork to fully track smaller irregularities as well, is more dive on braking & higher g-loads & perhaps a slightly lower max g load threshold...acceptable for solo riding sans luggage/travel kit at normal pace & those seeking the plushest fork performance, but starts to become a little less balanced with increased pace, loads & more technical terrain. Compared to the oem forks it's almost like having a steering damper on gravel FSRs with much less deflection on large loose rocks & potholes...the front end absorbs most of whatever it hits & tracks straighter. 

Rally Raid 6.0 Nm Fork Springs & 95 Nm Shock Spring (with correct Rider Sag & revalved/upgraded piston oem Shock)

I found the Rally Raid 95 Nm shock spring too stiff across the board for my 100 kg (220 lb) w/riding gear resulting in the shock feeling harsh, so reinstalled the 90 Nm spring when the shock was revalved with upgraded piston & repaired by Suspension Werx. See blog post here that includes differences between Rally Raid & K-Teck springs & the correlation of the Tenere 700 hydraulic preload & load compensation. While the 90 Nm spring needed almost 2x clicks preload vs the the 95 Nm for 30% rider sag, it provides better overall performance & dynamic range while still having enough clicks preload remaining for full travel loads & 2 up. A take-a-way was to not over prioritize how many clicks preload a given shock spring needs to achieve correct rider sag...a spring that provides correct sag with zero or little preload might be a desirable theoretical target, but may not necessarily be the best match for your riding, specific shock or suspension design.

Rally Raid 6.0 Nm Fork Springs & 90 Nm Shock Spring (with correct Rider Sag & revalved/upgraded piston oem Shock - current set up)

After experimenting with the Rally Raid 5.6 & 6.0 Nm front springs & rear shock 90 & 95 Nm springs I have settled on the 6.0 Nm fork springs with +1 click preload & the 90 Nm rear spring with +12 clicks preload for the best overall balance & broadest range of load, riding style & terrain capability. The revalved KYB shock with larger flow Showa piston brings the shock closer to the performance envelope of the Rally Raid 35mm Open Cartridge Fork Kit in most circumstances, with much better rebound control & will be good enough for how most actually use their Tenere 700, but will reach it's limits below that of the forks with increased pace, weights & more demanding terrain, particularly in terrain where shocks with separate hi/low damping circuits offer superior tunability & performance. 

I dialed in the suspension settings during a 10 day 3,800 km fully loaded, 1 up paved/gravel road trip of central & southern BC in Aug 2022 with this combo & settled in with adding 2 clicks fork rebound & 1 click preload & adding 5 clicks shock rebound & 2 clicks preload & vs my daily settings to compensate for the increased load & the suspension performed very well keeping the bike composed & balanced over a wide range of terrain & speeds in a manner that far exceeded the capability & performance envelope of the oem suspension. I switched bikes with a friend & former enduro/motocross racer who has a KTM 990 with suspension set up by Ian @ RidersEdge for a 200 km day of Cariboo FSR riding & he was impressed with my bike's suspension & that it performed similar to his. 

Final Thoughts

If you plan on treating your Tenere 700 to a 'forkectomy' & if your budget permits, the Rally Raid 35 mm Open Cartridge Fork Kit should be high on the list giving the bike a noticeably improved feel, performance envelope & range of adjustability that cannot be achieved via traditional revalving or piston kits of the oem KYB fork...providing a solid, refined & well damped feel + reduced dive & rocking horse effect with more tactile feel thru the bars. The independent rebound & compression forks & top mounted damping & pre-load adjustment allow for convenient & wide range of tuneability, including different weight fork oil if desired & even at the lowest damping settings 1 or 2 clicks effect discernable differences, with much firmer settings higher up the dials to cope with higher speed & g loads. 

Quality, properly set up suspension components can infuse a silky fluidness & responsive interface with road surfaces aiding steering, suspension & braking feel/performance, safety margins & reduce fatigue that can be appreciated with every ride & the Rally Raid 35mm Open Cartridge fork kit moves the Tenere 700 substantially in that direction. This fork kit has so much dynamic range & quality components that it can be tuned for extremely diverse loads & almost any type of riding short of hard core enduro, where closed cartridge designs are better suited, & is easily serviced without need of specialized equipment, a bonus for adventure travellers...it is a well sorted design that showcases Rally Raid's experience & expertise.

My take away from this suspension experience is, at the minimum, every rider should properly spring their bike for their weight & type of riding & set correct rider sag...benefits abound just by leveling the chassis & having the shocks resting higher in their stroke....plus don't be afraid to experiment. Thanks to John Mitchinson @ Rally Raid, who originally suggested in my initial consultation with him, the 5.6 Nm fork springs & the 90 Nm rear spring combo for my particular riding/set up & offered to include the 6.0 Nm fork springs so that I could compare them & later sent a 95 Nm shock spring as well...he seems to have a keen understanding of the Tenere 700, how his products interact with it & provides great customer service. 👍 

Tenere 700 Fork Options

Seeking tuning advice & servicing from experienced suspension tuners for your bike & type of riding is highly recommended & urge riders to learn how to & experiment with their bike's suspension adjustments. Performing basic adjustments, setting correct sag & maintenance provides a greater understanding & appreciation of your suspension...I have leant a lot during my Tenere 700 suspension upgrades, providing greater confidence in setting my bike up correctly, performing routine maintenance/servicing & troubleshooting issues in the field if necessary. Here are a few fork upgrade options progressing from least expensive & effective, of which all should include correct springs & sag settings for your weight:

• For those on a budget or only looking for modest improvements preload spacers, springs, revalving, different weight oil & air gap are options.
• K-Tech & others offer piston kits & springs for the oem forks (& shocks) that provide good bang for the buck for substantive improvements. 
• High end performance &/or longer travel options via open & closed cartridge kits are available from Rally Raid & others. 
• And for those seeking the beefiest, longer travel forks & possessing the technical expertise & equipment a pair of KYB SSS 48 mm Yamaha YZ450F dirt bike forks could be transplanted, as Cory @ Camel ADV did here...Note: 5 part series.

Detailed Rally Raid 35 mm Open Cartridge ForkKit install Video

by Marcus Palmehorn @ Everything Tenere

Detailed Fork Service Video Including Changing Fork Seals

by Marcus Palmehorn @ Everything Tenere 

MAD-TV Video Comparing 3 Tenere 700 Suspension Set Ups

Detailed comparison review of 3 Tenere 700s with correct springs/sag & 3 different suspension set ups over a variety of challenging Australian back country roads meant to expose their strengths & weaknesses: 1 with revalved oem forks & shock, 1 with K-Tech springs & piston kits in the oem forks & shock & 1 with Rally Raid 35 mm Open Cartridge Fork Kit & Adventure Shock.

Installation of Revised Compression Piston & Valve Assembly Dec 2023

The revised compression piston assembly finally arrived...thank you John! He claims that it produces 30% more oil flow making initial movement more plush & recommends using the same Motorex 5w Racing fork oil & amount as the original design (450 ml without spring & 120 mm air gap for normal riding or 100 mm for harder riding). It is possible that the revised piston shim stack is different also because it was included as an assembly, but did not compare it to the original stack or verify with John. 

I also noticed that the installation instructions available for download on their website for the Tenere 700 35 mm Open Cartridge Kit as of Dec 2023 is now version 5 vs version 3 that came with my fork kit in July 2021 & have much softer recommended damping clicker settings of 6 clicks compression & 4 clicks rebound IN from fully anti-clockwise (softest) vs clicker settings of 6 clicks compression & 4 clicks rebound OUT from fully clockwise (firmest) out of 24 clicks. This & a minor instruction addition at the end of part #3 on page #16 seem to be the only changes.

Because of my experience with the Rally Raid fork compliance gravitating to a livelier, tactile feel on initial travel & not fully absorbing smaller surface irregularities, even with the compression adjuster backed all the way out to zero, I opted for 2.5w Motorex Racing Fork Oil in combination with the higher flowing revised compression piston to establish a baseline of most fork compliance/suppleness attainable & will play with the 24 clicks of adjustment to see how it affects overall performance. A benefit of each fork performing separate rebound & compression vs the oem is that individual forks can have more dynamic range of tunability & can run different weight oils...have left the rebound fork with the recommended 5w oil as I was happy with it's performance. 

Revised Gen 2 Rally Raid Compression Piston & Valve Assembly

Rally Raid Gen 1 vs Gen 2 Compression Piston Assembly that flows 30% more oil 

Interestingly, the gen 1 piston has almost equal sized outside holes on both sides that are slightly smaller than the revised piston bottom side outside holes, while the top side holes are actually smaller. The included shim stack may be slightly different, particularly the top side stack...I did not lay them out for comparison to simplify installation & prevent any goof-ups on my part.

Right Fork & Rally Raid Compression Cartridge Removed from Bike

Rally Raid Gen 1 Compression Piston

Rally Raid Gen 2 Compression Piston Assembly installed

Tech Tips: It took about 1 min of heat gun on high on the black aluminum tube below the 32mm aluminum nut to break the blue locktite on the nut on the top side holding the piston assembly in place with the slightly smaller aluminum nut on the bottom in the vice. NOTE: Ensure that any aluminum thread fragments are removed & the threads on both the tube & nut are cleaned thoroughly. I did not use locktite when re-installing & tightened snug not wanting to damage the aluminum threads (Rally Raid did not provide torque specs). The Rally Raid silver stick on part # label had come off the black tube when draining the oil....so keep an eye out for it when you service your forks.

Clean all components & dry with lint free cloth. I don't have a cleaning tub so used brake cleaner. Apply a light application of fresh fork oil on all parts before assembly. 

I slid the new piston assembly onto a screw driver before cutting the zip ties holding the valve stacks in place & slid the screw driver into the shock cartridge damping rod shaft hole to preserve correct shim orientation/location & the lightly peened retaining nut went back on no problem (John had cautioned to be careful with the threads when re-installing the nut). Be sure to reinstall the compression piston plastic sleeve collar correctly.

The bottom fork lug nut required a gentle impact wrench application to prevent the whole assembly from turning during final torque setting.

The bottom of the black aluminum cartridge tube contains a valve integral with the screw in lower aluminum tube to permit oil flow from the shock tube to the fork tube

View from inside black tube

View from inside lower tube

Ride Review

As the bike is uninsured for the winter a full ride evaluation will have to wait until spring next year, but did sneak out for a brief ride in the apartment complex parking lot & lane across the street with a few speed bumps & the forks did feel a little more compliant & progressive at low speed. Full ride review to follow in the spring.

April 19, 2024 Update

Remove 30 ml of fork oil from each leg to tune for improved compliance.

OEM Rear Shock Revalve/Rebuild + Rally Raid 90 & 95 Nm Rear Spring

Click here for my Dec 2021 blog post about my oem rear shock revalve/rebuild by Suspension Werx + RR 90 & 95 Nm rear springs & ride review.

SKF 43 mm Fork Seal Kit for Tenere 700 - Installation to follow at future service

Suspension Tools

Tusk Fork Oil Level Tool, Tusk 43 mm Fork Seal Driver, TR Deisel Yamaha Steering Head Ring Nut Wrench

Yamaha Engine Alignment Tool part #90890-11097-00 used for swing arm removal/install...allows for removal & setting the correct torque of the adjusting bolt.

Ceiling Hoist

The ceiling hoist works well for front wheel removal, although the 0.55" taller 140 80/18 rear Motoz Tractionator GPS tire vs the oem 150/70 18 Pirelli Rally STR reduces rear tire floor clearance when on the SW Motech center stand (adding a spacer under the center stand improves rear wheel clearance). Using a floor jack under the front of the skid plate provides additional stability.