Anyone? Bueller?

 

I've not seen a vintage cartridge fork like this installed on the SV but I'm sure someone must have done it at some point. You can install just about any fork into another bike if you can sort out the steering stem fitment issues. If the steering stem length is close to the SV or more modern GSXR stems and you can find stem bearings that will fit the stem and neck on the SV then it is theoretically possible to use these forks.

OR you can go for a more modern GSXR fork, like maybe an 06+ fork with radial brakes and a 0.90 spring and have fewer fitment issues. The downside is the cost, of course.

If you go with the forks you have now the parts to rebuild it are still available from Bike Bandit so you're okay there. The design of the fork is basically the same as a later model Showa fork, although there may be specific differences I'm not aware of.

Hopefully, someone will chime in with more specific information. Good luck with this.

 

Here is a vintage link:
http://www.svrider.com/forum/showthread.php?t=45179
Nothing listed for 1000 prior to 2001 , and no 1100 specific
This is the search line I typed into Google Search if you want to dig a little deeper.

""fork compatibility"guide" site:svrider.com

 

Thanks for the feedback. I'll pull them off and take some measurements to compare to 04-05 GXSR600/750/03-04GSXR1000 specs in the chart to see what fitment challenges there might be. The ignition mount is in the center of the top clamp, but that's solvable.

I see that Race Tech has bushings, and I found AllBalls seals on Bike Bandit, so for about $50 I can freshen them up, so that's good (and an added cost no matter what I swap to). I just don't know if they are worth the time.

The brakes are axial mount, but they're big 6-pots and were one of the better aspects of the bike back in the day.

I guess my question is more about 1994 KYB 41U vs 2004 GSXR parts. These are preload, rebound and compression adjustable (not high/low speed compression, though), but how much improvement in valve technology was there over that decade? Is a 2003 cartridge worlds better than a 1994?

 

I suggest you pull the forks apart and check the bushings before buying replacements. If they are like most cartridge forks, those bushings are press fit and require a puller to avoid damage. If the bushings are okay then just leave them in place and change the seals. I would only use OEM fork seals and dust caps to avoid fitment issues. Even Race Tech uses the OEM seals.

I haven't been inside the early Kayaba forks so I don't know what the compression and rebound valving looks like - sorry. However, your forks are the typical cartridge design that is very similar to the later GSXR forks up until they changed to the big piston design. I would imagine the valving is very much the same - ie; a single shim. With that said, the Showa fork design during the later SRAD years and into the mid-2000's (possibly later) is thought to be one of the best forks ever put into a production motorcycle so there may be significant differences after all - I don't know.

Personally, I would just look for a K4/K5 GSXR front end and use that. It will go in without problems, parts are still readily available and it comes with radially mounted 4-piston brakes that are as good or better than those monster Nissin 6-pots. Moreover, they come stock with a 0,85kg/mm spring, unlike the 0.78kg springs in the 1100 forks, so they will support a rider up to 200#. I can tell you that they tune very well, especially if you have a good rear shock.

Good luck with your decision. Before you finalize things, check with Sonic Springs or Race Tech and see if they have beefier springs for that fork. If they don't make them for your fork then that would be a deal breaker for me.

 

Good point. You're right about that. If I can't get heavier springs, then it doesn't really matter.

I'm not trying to be cheap. I'm just trying to find a use for this stupid 1100 in my garage. I also like the idea of clip-ons above the top clamp.

I'll go ahead and tear the fork down anyway and see what the valves look like, and I'll check on springs.

 

Yeah, I like the clip ons on top, too. Plus, your bike being a naked, there are no fairings to clear so it would be sweet if this worked out.

I would check on spring availability before tearing the forks down - no springs then end of story.

Keep us posted on how this turns out. I, at least, am interested.

 

Sonic has 0.90 and 0.95 springs listed on their website for 1991-1994 GSX-R1100.

I'll go ahead and email Rich and see what insight he might have.

 

Sweet! Main obstacle down.

Now you have to sort out the stem bearing issue. I'm going to bet the bearing size is the same as modern GSXR forks but you have to check. Bike Bandit lists different part numbers between a K5 GSXR 750 fork and yours but the size of the upper bearings are the same. I can't find the size for the lower bearing for your bike.

One thing that might work is to call or email All Balls and see if they have a conversion kit. If they do then the homework has been done for you and you can probably do a swap. It is very likely that they will know the bearing sizes of your stock 1100 stem.

I would suggest you do some careful measuring of your bike's stock geometry before you commit to the project and tear your bike down for a swap. At the very least, check the length of the fork legs under the lower triple to the center of the axle. I would want to be sure the location of that measurement on the 1100 forks is similar or at least adjustable to get close to the stock length. Hopefully the clamping areas and the triples will allow enough adjustment to tune your turn in.

Another area to look at is the front fender. You need to make sure that it won't smash into the radiator at full fork travel. Not likely but you never know.

This is going to be interesting. You are very likely going to need custom brake lines and control cables but I can't see any major obstacles other than those discussed.

 

All Balls has a fork conversion finder on their homepage. Enter your bike and it lists all the possible conversions and the required bearings.
You will be amazed at the number of possibilities.

 

The All Balls conversion tool doesn't seem to be working. I tried chrome, IE, and firefox, and on two different computers, and no dice. Just stuck on "Loading."

I'll mic them when I get a chance and see if they match any of the other common Suzuki sizes.

Rich @ Sonic suggested I ask Zoran about the valves, so I'll do that, too.

 

They have the bearings for both bikes:
94 GSXR = 22-1004
03 SV650 = 22-1003

Call them and ask if these will interchange or if they have an option. They do not list bearing dimensions so we cannot tell.

 

Both bikes have same bottom bearing, 30 x 55 x 17
gsxr has 25 x 47 x 15 upper bearing (same as 1st gen sv)
2nd gen sv has 30 x 55 x 17 upper bearing.

To use gsxr triples you would need 25 x 55 x 17 bearing which is not available. Your option is to swap stem, can use newer gsxr stem or 2nd gen sv stem. Or make bushing for upper bearing.

 

Tovar to the rescue!

So, if he presses out his Gen 2 SV stem and presses that into his existing 94 lower triple and used a Gen 2 SV upper triple bearing, that would work?

 

Correct, assuming stems are identical in diameter where it is pressed in to triple.
2nd gen sv and newer gsxr have same diameter stem there. But he has 94 gsxr which has steel stem and it could be slightly different like 1st gen sv is.
Stems are easy to press in/out with hydraulic press so it should be no problem finding out.
Or even easier he can just send me gsxr triple and I can make it work for him

 

Outstanding! Thank you for the info, Tovar.

 

Great info! Thanks!

I've got a hydraulic press and a lathe, so I've got a couple of options there. I'm inclined to leave the factory SV triple clamp alone, but it'll depend on the GSXR stem length and diameter at the boss where it is pressed into the lower clamp.

I haven't put much work into this yet because I'm trying to squeeze-in as much riding time as I can while the weather is good.