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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.
 
#232 ·
TL wheels are 7mm wider at the wheel bearings and 2mm wider offset between the rotors vs GSXR wheel.
But you can make them work.
I used a silver Busa wheel on my swap originally - like you say, they match up with the silver rear wheel on the 03/04s.
http://forum.svrider.com/showthread.php?t=86338

You will need to use the SV1K 310 or the TL/Busa 320 rotors (5mm caliper spacers required with the latter)
You can probably get away without machining the rotors as I did - the pads should accommodate the difference. Then you need a smaller right-side axle spacer (-3.5mm machined off std length)
The axle will protrude out of the fork leg on left side by 3.5mm
 
#233 · (Edited)
You can probably get away without machining the rotors as I did - the pads should accommodate the difference. Then you need a smaller right-side axle spacer (-3.5mm machined off std length)
The axle will protrude out of the fork leg on left side by 3.5mm
Is this the stock axle for the GSXR750 front end, or did you put the Busa axle in to the GSXR front?

Maybe I'm better of buying a set of front and rear ends for a GSXR and selling the parts I don't need. It will probably come down to the same price tag but I'll have a original GSXR wheel which is plug and play to the front fork I have my mind set to. I can always buy a black rear wheel from a SV650S to match the new front wheel.

I'll go buy some bits this afternoon, even when the bike is not back from the towing company yet...
:rimshot:

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#235 ·
hi D'Ecosse, i'm a Aircraft mechanic out of Hayward and have been lurking around the forums since i recently picked up a first gen sv for commuting purposes. I started collecting parts for a gsxr swap and so far i have a complete 05 gsxr 600 front end, triples, axle and calipers and 2 days ago i bought some "safety" yellow rims off a 06 gsxr 750, much to my chagrin they seemed to be less plug and play than i was anticipating. is this meerly a rotor issue or will i need a axle off a 06? i actually listed the rims back on craigslist and began looking for some 04-05, was this premature? heres the rims
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#236 ·
I started collecting parts for a gsxr swap and so far i have a complete 05 gsxr 600 front end, triples, axle and calipers and 2 days ago i bought some "safety" yellow rims off a 06 gsxr 750, much to my chagrin they seemed to be less plug and play than i was anticipating.
Those wheels will work for you. Front is 310mm rotors and you need 5mm spacers. You use 05 axle. other than caliper spacers it is all bolt on.
 
#239 ·
^^^ As tovar says, everything will work well so keep them!

You need to get the excellent modified Rear Wheel Kit (exchange) from TWF Racing

You will need the GSXR Sprocket carrier though

And front is just the 5mm caliper spacers with the std 04/05 axle.

Give me a shout when you are putting together if you need someone looking over your shoulder.

p.s. those rotors lend themselves well to symmetrically spacing the trigger magnets for the Speedo Detector
 
#240 ·
wow thanks guys for the quick responses and shameless spoon feeding, any ballpark idea what TWF charges for their rear rim wheel kit and machining services? is a swing arm mod from a 06 gsxr not worth the effort? i do have access to a full machine shop here at work but sadly do not have the experience using the tooling, and it seems the only way i could bribe the older mechanics i work with to do it is by majicaly granting them a day off.
 
#241 ·
... any ballpark idea what TWF charges for their rear rim wheel kit and machining services? ....
Click on the link I posted - has the price right there - includes the machining of the sprocket carrier and the brake caliper hanger. You supply those, you get them back ready to bolt on, along with the captive spacer kit.
As mentioned earlier, you will need to get a GSXR Sprocket carrier - the brake caliper hanger is the OEM SV one (or optional for Ducati cylinder which like it says gets rid of the torsion arm)

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The difference is Zoran at TWF does all the work himself on his own machine tools. You can be assured of top quality fit.

Don't think you will see/feel any real benefit from GSXR swing-arm swap other than bling.
If desired, you could always add braces
 
#249 · (Edited)
As I scored a set of front and rear wheels of a 07 GSXR750 I also ordered a conversion kit from Zoran!
He's very fast at responding to emails and seems to take care of machining the parts just as fast :naughty:

I'll probably have the kit in the Netherlands faster than all other parts for the front and rear conversion... including my own bike :magpie:
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#257 ·
My fork swap is complete. Here is how I made it work:

Fork legs, bottom triple, front wheel and brake calipers come from a GSXR 750 k6/k7
Top triple comes from a GSXR 750 k4/k5 to keep the steering lock as standard. This requires the bore to be enlarged from 25mm to 28mm so it will fit the k6/k7 bottom triple.
Clipons are from a TL1000S to keep a similar seating position as a stock fork.

It looks like this :naughty:
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#262 ·
Steering stops and lock should both work fine I think. There might be some interference between controls and fairing at full lock.

No clue if you're interested, but I've got a Spiegler top clamp for that that would allow you to run conventional handlebars.
 
#264 ·
I believe the GSXR clipons will hit your fairing, although I can't guarantee it. Riser clipons, such as those from the TL1000S, would solve that problem. Note that it's not horrible, just annoying.

Most people go with front wheel, probably because it's easier. You'll need a hall effect sensor and magnets either way but I'm not sure where the best place to buy them is.
 
#268 ·
I've been accumulating parts for my swap for a couple months now. I have a hall effect sensor and magnets for the speedo fix.

Is there any reason I can't put the magnets and sensor on the rider's right side of the wheel? I think all of the photos I've seen have it on the left. When doing the swap, I'll also be installing SS Spiegler lines that follow the stock routing (i.e., one line out of the MC, double bango at the right caliper, and one line over the fender). I'd prefer to have the speedo cable zip tied to the brake line for a cleaner install rather than have lines going down each fork leg (which is why I passed on having two lines from the MC in the first place). Anyone see this as a problem?