Suzuki SV650 Riders Forum banner

GSXR Fork Information / Permutations

1 reading
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:

Image


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:

Image


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

Image



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

Image



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

Image



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

Image



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

Image



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

Image


All other GSXR models

Image



Yamaha Monoblock (R6)

Image



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

Image



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.

Image


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.

Image



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

Image

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.
 
#560 · (Edited)
I have a question about the wheel matrix on page 1, if I have k7 GSXR750 forks and axle, can I use newer/older wheels? k1+ GSXR600/750 and GSXR1000.

I wasn't sure what the bore is for on that matrix chart, is that the size of the axle hole?

The wheels are comparable fitment for all 01+ GSXR;
however the axles change with the fork generations;
Does that mean I need to change my axle bolt to match the year of the wheel? or do I keep my axle bolt matched to the year of my forks and I can just use any wheel as long as the rotor matches the wheel?

Thanks
 
#561 ·
The wheels are all same fitment re space between bearings - what changes is the rotor size and fitment; so you need to look to the chart to see what rotors fit the wheel you end up with.
You can accomodate different diameter rotors with caliper spacers; but you must be sure that rotor you select is compatible with the hub & bolt pattern on the wheel you choose.

Axles/nut/bolt have to match generation of forks, not wheels
 
#564 · (Edited)
That's what I get for trying to do math late at night.:dizzy: It's going on an 03 SV1000. I've already done the SV650 with 04/05 GSXR600 front end with the R1 monoblocks (Zoran machined the calipers). I've just got to make a new steering lock nut tool and I should be set. Yeah the speedo setup was a pain on the 650! I'll be running a vapor on the 1000.

For anybody swapping front ends here's a link on how to make the steering lock nut tool.
http://www.gixxer.com/forums/showthread.php?t=273512

And here's a thread that tells you what to torque it to.
http://www.svrider.com/forum/showthread.php?t=36830
 
#565 ·
That's what I get for trying to do math late at night.:dizzy: It's going on an 03 SV1000. I've already done the SV650 with 04/05 GSXR600 front end with the R1 monoblocks (Zoran machined the calipers). I've just got to make a new steering lock nut tool and I should be set. Yeah the speedo setup was a pain on the 650! I'll be running a vapor on the 1000.
Did you redo the speedo setup I did on it? I thought it was pretty slick and easy to work with/around.

Still sporting the 650?
 
#568 ·
Sup, Shaggy. Your setup is still the same but I did re route it. I had to help a local guy with his swap. It could have been a lot harder but I had mine (yours) to use as an example so it helped. I still have the 650 but I found a 1000 too cheap to pass up. The 1000 is going to be a lot easier than the 650 besides fabbing up a subframe.
 
#569 · (Edited)
Does anyone know what the OD of a K6/K7 GSXR600 front axle shaft is?

I got a spacer and it didn't fit, so I wanted to check whether the spacer is wrong or the axle is wrong, the axle style looks correct (screw on the end), and I thought K6+ all used the same axle's but the spacer I got was from a K11/K12 and it's too small to fit on the axle shaft.

Thanks

EDIT: New wheels have a spacer so not worried about it, but I will measure them to answer the question in case anyone else cares.

I would like to know from those who are doing the swaps, did you get steering or wheel bearing kits?

Like these:

http://www.ebay.com/itm/140936515996
http://www.ebay.com/itm/140938532094

Also wondering if I should get a master cylinder rebuild kit, or just wait and see how it feels after put on and flushed.

Thanks
 
#573 ·
There's no rake in the triple clamps, only offset. You're thinking 32mm offset, not 32 degrees rake.

03 GSXR600 didn't come with USD forks.
 
#578 ·
bluecurvy27 - the second picture in the first post of this thread shows the triple clamp and the triple clamp offset.

You need to match the offset in the upper and lower triples.

I wasn't sure if certain offsets were needed by certain gen's but I guess they wouldn't.

Correct me if I'm wrong, but the rake will be set by the angle of the steering stem mount on the frame and the length of the forks.

I would also suggest you post a picture (or match your forks to the pictures in the beginning of the thread) to make sure you know what year your forks are, that will determine what you can and can't use easily.

To give you an example, I have K7 GSXR 750 forks, this limits me to using K6/K7 GSXR 600/750 lowers (53mm) unless I want to use a shim, then I can use other years of lowers.
 
#581 · (Edited)
I'm seriously thinking of getting that all balls steering bearing kit, dump those caged balls.
Ok decided against it, at least the all balls ones


This quote did it for me:

I prefer balls cuz i believe they add less friction into the steering system and therefore provide a superior feeling for the signals the front tire sends to the rider.

They do require more maintance and more frequent replacement, however, and unless someone follows the service manual's re-greasing mileages (about 12-15k i think) they are usually spoiled by about 35,000 miles.

It's not about better technology, it's about better feel.

Allballs is Chinese-made cheap junk typical of low quality PRC products. If you want them for the steering head they may prove satisfactory, but i'd never risk allballs in the wheel bearings.

High quality bearings don't come from China; they are manufactured in Germany, USA, Japan or wherever the same standards of materials and manufacture apply. Who would risk flying in a Harbor Freight airplane ?
 
#586 ·
wow I had forgotten how much of a PITA it was to put pics on svrider......I think the last time I used photobucket was also for here




My forks and the part #, I was told they are from an 03 GSXR 600, but have been told in here that o3 600s didn't have USD Showa forks, so can anyone narrow down what these came from as I assume I need it specificly for an axle and to get the diameters for triples?