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GSXR Fork Information / Permutations

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528K views 1.1K replies 197 participants last post by  Bremsen  
#1 · (Edited by Moderator)
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:

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Acknowledgments 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:

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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 of 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

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

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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

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

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

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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
No interchangeable re pads however

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All other GSXR models

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Yamaha Monoblock (R6)

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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

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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 the front of the speedo for naked)
It has a 30mm offset and a 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 the 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 with the wheel straight ahead, as opposed to the 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 a 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 a 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.

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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 the wheel & right fork leg.

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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 sizes also
Gen 1 SV650 is the same bottom bearing but requires a 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

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Mix n Match Capability for Wheels/Rotors:

01-04 1000 and 01-05 600/750 and SV1K all are the 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 the wheel only.

09+ 1000 and 08+ 600/750 take 310mm rotors only - note that these rotors are NOT compatible with the group immediately above & vice versa.
 
#397 ·
what is or where can i find out the stock spring rate of k8/k9 gsxr750? i haven't a service manual of it, so its kinda hard to find the answer.

thanks!
 
#399 ·
ok, thanks. is there any doubt? also, fork oil? i've heard stock 7.5w


and i read that its supposed to be the ideal spring rate for 165-170 lbs w gear.
how come thats so diff from the .85 that is recommended in sv forks for that weight?
 
#400 ·
Not sure what oil suzuki puts in there. W means very little.
1.0 is to stiff for sv and that rider weight. .85-.90 is better.
Gsxr has more power and transfers load different, reason for stiffer rate. There is more to it than just simple weight. Combined weight bike and rider is just guide or place to start. Than you factor other stuff like power, load transfer, riding style...etc.
 
#401 ·
sounds great! thanks for wisdom.
 
#402 ·
I wrecked my 06 SV650N, and the front forks are both bent from impacting the curb. I'd like to install a GSXR front end, in place of the now unusable stock one, but don't want to wire in a new instrument cluster (such as the Vapor) in place of the stock cluster. Is there a way to keep the stock gauge setup when installing a GSXR front end? I'd like to upgrade everything downward from the triple tree..
 
#404 ·
Is there a way to keep the stock gauge setup when installing a GSXR front end? I'd like to upgrade everything downward from the triple tree..
The -N has brackets that fit over the 41mm fork tubes to hold the headlight etc. GSXR forks come in 45mm or bigger. So you'll have to source appropriate hangers. I do seem to recall some headlight supports on eBay. The problem with the cluster is that most of it mounts to special tabs on the upper triple clamp. Said triple isn't remotely compatible with any year GSXR from the last 15 years.

There's not enough meat to bore the holes out so you either need to source 41mm forks (be they ZX6E/F, bandit, SV, Katana) for the uppers or replace the triples, forks, calipers, fender, and ?maybe? front wheel and still have to figure out how to mount the gauge cluster.

There is also the option of putting GSXR/ZX6F guts inside SV forks if you want to keep your bike looking like an SV but have vastly better and adjustable suspension at your fingertips.

I happen to have some ZX6F forks laying about if you're interested.
 
#403 ·
There's no need to install a new cluster. You WILL however have to wire in a new speedo sensor as the stock one does not work with the GSXR front end. All said, it's soldering/shrink wrapping 3 wires and putting some magnets in your wheel, very easy. You should read through these threads as this is all thoroughly explained and many have even put up how-tos on the various parts.
 
#415 ·
I've tried to search and read as much as possible...

I wanna swap the front end of my 2004 SV 650N to a gixxer end as well..

After I will work out which wheel to use and what triples and what forks, can you tell me how do I work out the steering stop issue? I assume if I put gsxr forks/triples/clip ons....it will slam into the tank.

If this has been discussed already,would you be so kind to give me the link or point me in the right direction?
 
#424 ·
I've looked through this section and couldn't find a definitive answer, but I think it's possible... Just need confirm for you guys.

For a 1st gen swap with SRAD triples, wheel, and axle combined with lets say 04/05 GSXR forks and brakes. Can we used SRAD rotors? Based on the matrix's out there - no spacers/shims needed correct?
 
#433 ·
I've read this whole thread, and still have a question.

Regarding the thin spacers needed, such as to run the R1/6 calipers on the 310mm rotors, is there any issue with loss of engagement on the caliper locating dowels? I don't have the parts yet, so I'm not sure what engages on what. But there's some discussion in here of the bolts carrying shear loads. Just looking at the parts, it looks like the calipers are supposed to pilot on the steel dowel rings that are pressed into the fork bottoms, and the bolts are only loaded in tension. The dowels are pretty short.

Does 2mm risk losing engagement of the straight sections of dowel and caliper? Whatever the overall height, both parts are likely to have chamfers of some size. Would an ideal system have either longer dowels machined, or maybe dowels with a flange to make it an integrated dowel/spacer combo?
 
#434 ·
I don't have dowels at all. Torque right and no problem.

If using 05+1k/06+600/750 forks and 310mm rotors you get full pad engagement with no spacers. I've personally done this, 07 750 forks and SV1k rotors.