EPM Performance in New Jersey came through for me with the fork upgrade on the Ultimate Motorcycling Honda CRF300L Rally Project Bike via the YSS Fork Cartridge Kit CO208-900TRC-01 from Thailand. The YSS Suspension kit requires disassembly of the fork tube from the axle lug, which proved to be an issue, even for an experienced suspension shop. Once installed, the fork upgrade was helpful for any style of riding, though obviously most valuable to aggressive riders.
The main issue I had with the stock Honda CRF300L Rally suspension was with the rear shock being so soft and springy that the bike would bounce over the kickstand and fall over almost every time I dismounted. That was remedied by the YSS MG456 reservoir shock sprung for 220 pounds. I installed that myself about nine months ago, and it totally changed the bike for the better. I waited to install the YSS fork kit until I already had the bike on a stand to do the 550 Performance 91 Octane Stock Improved upgrade.
The kit replaces the stock damper rods with a fully adjustable active damping system. Specially designed fork caps allow for tuning spring preload, rebound damping, and compression damping. The fork springs are matched to the rider’s weight, and the kit is specific to the Honda CRF300L and CRF300L Rally.
The fork kit also raises the front of the Rally about half an inch, further increasing the already tall seat height. The instantly noticeable benefit of the YSS Fork Cartridge Kit install is greatly reduced front brake dive. I use the front brake way more than the back, both on and off road, and this was worth the $689 MSRP, plus the shop install charge, by itself.
Once I got off-road, the new cartridge damping smoothed out much of the handlebar buffeting I had been experiencing for hours at a time. Deflecting off rocks is greatly reduced, and I have more confidence in the front tire going where I point it in rough terrain.
The few low jumps that have crossed my path have had controlled landings without bouncing or bottoming out. During spirited riding through the twisties, the front end is more stable, with no delay or sloppiness. The Rally has been surprisingly stable at freeway speeds, and three hours at 70 mph feels almost as stable as the Ultimate Motorcycling Yamaha Ténéré 700 Project Bike did.
Getting the fork legs off the bike only takes about 10 minutes of unbolting, starting with the front wheel and ending with the fork tubes sliding out of the triple clamps.
I never considered installing the fork upgrade myself. It requires special tools, and aiming a 600°C heat gun at the axle lug. I spoke with several local suspension shops near me in Portland, Oregon, and they were all willing to attempt it. However, they all warned of the same potential issue: stripping the threads on the fork tubes due to the forged axle lug setscrew potentially fouling the tube’s threads.
Important caveat: Honda does not condone separating the fork tube from the axle lug. They do not sell them as separate parts, so you are at your own peril of a $600 fork leg replacement if it doesn’t work out.
As my suspension guy explained it, the right fork came apart easily, and the cartridge installed smoothly with no issues. He was expecting the left to go just as smoothly. He made the same moves, but the axle lug would not unscrew from the fork tube. More leverage didn’t help, until he did a slight tightening. Then it finally unscrewed, scraping off half an inch of threads and requiring the fork tube and axle lug to be replaced. Ouch, to the tune of $600.
With that painful lesson out of the way, the YSS Fork Cartridge Kit turned out to be a worthwhile upgrade for my use of the CRF300L Rally. That’s especially true when paired with the YSS shock already on the bike.
The improvement in brake dive control and front-end composure makes the Rally feel more settled across a range of conditions, from rocky forest roads to long stretches of pavement. At the same time, the installation risk is a real consideration that should not be minimized. Riders who mostly commute or casually explore gravel roads may not find enough benefit to justify the expense and potential complications.
However, for riders spending long days off-road or pushing the Honda CRF300L Rally harder in rough terrain, the front end now feels far more controlled and predictable than stock. If you want top-notch suspension and are prepared for the expense and installation risks, the YSS Fork Cartridge Kit pairs beautifully with the YSS MG456 reservoir shock when you’re serious about suspension performance on your CRF300L.
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In our first segment, Don Williams and Nic de Sena chat about the latest Yamaha MT-07. The amazing motor in the Yamaha is mostly unchanged, however just about everything else with this bike has changed. Don and Nic have extensive experience riding this beast and you’ll hear both their likes and a couple of dislikes too.
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Our guest for this episode is Nikolas Lazos, a 15-year old young man from Melbourne, Australia who starting racing in the Supersport 300 category in Australian Superbike last year. Nikolas had an awful crash at the tail end of last year that put him out of contention for the Championship. Teejay chats with Nikolas about his journey so far, and the physical and mental challenges he’s facing coming back from injury.
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Here’s quick reminder to check out our monthly digital magazine. It’s filled with everything you want to read on motorcycling, including some things you’ve probably not seen elsewhere. It’s absolutely free and you will find it on the Apple App Store and of course on Google Play as well.
Don’t forget to leave us your comments on our social media—we’re on all the usual platforms at Ultimate Motorcycling. We love hearing your feedback… so good or bad, please let us know what you think. If there’s something you’d like us to cover, we’d love to hear those ideas too!
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