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Here is a summary of the different models of USD Radial forks used on the various Suzuki models.
Hopefully this will concentrate all the dimensional information on the most popular SV/GSXR fork conversion possible configurations.

Let's start with the matrices for the dimensions of the various fork models:



Acknowledgements to Sam over at TL zone for initiating the primary chart creation and to all those who provided the data for it.

This excellent illustration courtesy of jeff721 will help indicate to what the measurements in the chart refer:



Of course there are the non-radial USDs used on the 01-03 750 and 01-02 1000 but the Radial versions seem to be the most popular, so that is the focus for this post.

So - looking at the primary area of interest for GSXR Radial Forks:

2003/04 1000
Gold/black inner tubes; gold calipers
300mm rotors.
850 springs
32mm offset; 54mm lower clamp
Right offset ignition top clamp, 28mm bore




2005/06 1000
Bronze/black inners; black calipers
310mm rotors
950 springs
30mm offset, 54mm lower clamp
Center ignition top clamp, 28mm bore




2004/05 600/750 (same)
gold/chrome legs, gold calipers
300mm rotors
850 springs
30mm offset, 54mm lower clamp
Right offset ignition top clamp, 25mm bore




2006+ 600
gold/ chrome leg, black calipers
310mm rotors
900 springs
30mm offset, 53mm lower clamp
Left offset ignition top clamp, 28mm bore




2006+ 750
black/ bronze leg
310mm rotors
1000 springs
30mm offset, 53mm lower clamp
Left offset ignition top clamp, 28mm bore




Calipers:

03/04 1000 and 04/05 600/750 (fit 300mm rotors std)

* the 03 1000 calipers are 4 pads per caliper - look the same as the two pad variant
Not interchangeable re pads however



All other GSXR models




Yamaha Monoblock (R6)




Caliper/Rotor Matrix:

Calipers can be utilized from all the models above, by using spacers* per this matrix.
* Note that although for some sizes it says N/A, this means the combo would be too tall;
however you could actually machine the caliper (or fork leg stanchion) as opposed to a spacer




Triple Clamps:

You can mix & match a bit here:
The ideal top clamp I believe would be the 04/05 600/750 clamp
This has ignition offset to the right (same as SV and more conducive to the Vee shape of front of the speedo for naked)
It has 30mm offset and 25mm bore.
Direct fit on 04/05 l600/750 lower triple clamp/forks
To fit on 06+ 600/750 forks/lower triple, bore stem hole to 28mm
To fit on 05/06 1000 bottom triple, bore stem to 28mm

If you have no access to machining, then 05-06 1000 top clamp will fit directly on the 06+ 600/750 steering stem. This clamp has ignition 'straight ahead'. The steering lock WILL lock, albeit it with wheel straight ahead, as opposed to conventional full left position.

06+ 600/750 top clamps obviously 'fit' their own forks/bottom triple, however the ignition is offset to the left; it requires some machining of the ignition module to avoid interference with the frame on the left side and the steering lock will not function without drilling frame. This makes it less ideal choice.

Bottom clamp:
03/04 1000 has 32mm offset, 54mm bottom fork dia and 25mm stem
05/06 1000 has 30mm offset 54mm bottom fork dia and 28mm stem
04/05 600/750 has 30mm offset, 54mm bottom fork dia and 25mm stem
06+ 600/750 has 30mm offset, 53mm bottom fork dia and 28mm stem

Note that 06+600/750 forks are 53mm at the bottom clamp diameter - the others above are 54mm; so consider that as you wish to mix/match bottom triples & forks.

Axles:

The wheels are comparable fitment for all 01+ GSXR;
however the axles change with the fork generations;

For the first group of forks per the caliper table above (03-04 1000 or 04-05 600/750)
uses an axle & collar nut (same as SV1K actually)
Note that there is no additional wheel/axle spacer required.



For the second group of forks (05+ 1000 or 06+ 600/750)
the axle has a threaded bolt, rather than a collar nut, with a separate spacer that goes between wheel & right fork leg.




Steering Bearings:

All GSXR forks in the range above have 30/55/17 top & bottom bearings.
All Gen 2 SV650 and SV1K are the same size also
Gen 1 SV650 is same bottom bearing but requires special top bearing from TWF Racing.

Wheels:

All GSXR wheels after SRAD will fit any GSXR forks described above
The rotors change sizes (and fitment) however


Mix n Match Capability for Wheels/Rotors:

01-04 1000 and 01-05 600/750 and SV1K all are same wheel dimensionally;
Will take 300mm rotors from 03-04 1000, 04-05 600/750;
Will take 310mm rotors from SV1K;
Will take 320mm rotors from any 96-03 600/750 or 01-02 1000 or TL, or Hayabusa

05-08 1000 and 06-07 600/750 take 310mm rotors only, from these years of wheel only.

09+ 1000 and 08+ 600/750 take 310mm rotors only - note that these rotors are NOT compatible with group immediately above & vice versa.
 

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Wow!! Many thanks.

I am a noob on this forum and it really is nice to see that the experts here are willing to share their knowledge and will expend the time to format and present it.
 

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You can mix & match a bit here:
The ideal top clamp I believe would be the 04/05 600/750 clamp
This has ignition offset to the right (same as SV and more conducive to the Vee shape of front of the speedo for naked)
I assume this is only for the 2nd gen? or would the 04-05 triple clamp work with the 1st gen ignition housing also?

My second question is if I wanted to use a 06 gsxr wheel with 04/05 forks would a 06+ axle be compatible?

I plan on doing the swap next month after I'm finished rejetting and syncing the carbs.
 

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Discussion Starter #6
... or would the 04-05 triple clamp work with the 1st gen ignition housing also?
The question of first gen triple tree fitment only differs with respect to the steering stop issue - all GSXR bottom triples have compatible Steering Stops with SV Gen 2 frames, but do apply for Gen 1 - so Gen 1 requires a different (auxiliary) steering stop method.
You could also use an 05/06 1000 top clamp (straight ahead ignition) with 04/05 bottom triple, in this case you would require a 28/25mm spacer bushing (or just use bottom triple from same 05/06 1000 set, or just the steering stem even)
SRAD (96-99 750) triples have compatible steering stops for Gen 1 Frames; however then you need additional axle & rotor spacers.

.... if I wanted to use a 06 gsxr wheel with 04/05 forks would a 06+ axle be compatible?...
Wheel is compatible with the forks, but the axle is not.
Note also that the issue with the caliper / rotor size compatibility
- the info is all there in the opening post, you just need to digest it.
 

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Is 01/02 1000 a 28mm stem? I've got a Spiegler kit that I believe is for one, and just realized that the hole in it is larger than the 00-03 750 lower triple that I have.

If so, where can I get a bushing?
 

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Great post D'Ecosse. Is there any value in adding the Gen 2 SV's stat's to the first matrix for comparison purposes?
 

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Discussion Starter #10
... If so, where can I get a bushing?
I can turn one out on the lathe - send me PM

.... Is there any value in adding the Gen 2 SV's stat's to the first matrix for comparison purposes?
Not sure what benefit that will serve to be honest - chart is about understanding the difference of what the specs are for the different USD components from a selection perspective and how they might potentially interchange with each other amongst the different years/models. None of the SV components (forks/triples/wheel/rotors/calipers/axle) are re-usable with any of the USD options so they don't really play into the mix.
i.e. the SV dimensional info becomes somewhat irrelevant.
 

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- the info is all there in the opening post, you just need to digest it.
Dammm skippy it is! Thanks for remaking this thread into a one stop deal.
NOOBS!!! READ THE OP OVER AND OVER AGAIN AND IT WILL ALL COME TOGETHER!!!
The only thing you left out is the Speedometer setup and fenders. Maybe another thread just for that would suffice. That way this thread hopefully doesn't turn into a volcano of questions that get asked over and over again like the old "NEW" one.

above post might be a good reason to put the SV stock specs up for comparison
 

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So I tried searching around... Is it not possible just to swap out the actual forks, not the entire front end??

-B
No... you won't be able to. The SV's triples aren't compatible with GSXR forks because they have a much smaller diameter... 42mm vs 50/54mm. Which means you definitely can't use an SV's axle and wheel.

You can how ever change out the internals of the SV forks... a common mod is stiffer springs from race tech/sonic springs, emulators, and heavier oil.. or you can go all out and get an ohlins or AK20 setup in your forks.
 

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I thought it was 41mm? Anyway, it doesn't fit.
 

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Discussion Starter #18
I thought they went bigger in 03.
what is offset on the 01-03 750 tovar?
01-03 750 clamp & 01-02 1000 look similar but different part number - so either stem diameter or offset must be different (or even both!) ?
 

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Not sure, I think same as 750 of that gen.
I believe stem size changed in 03 and 01-02 was direct fit to 00-03 750.
I have 03 1k upper triple and it is bigger stem.
 
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