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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

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.
 
#313 ·
So I got the 06-09 GSXR-600 forks mounted up on my 04 SV 650. I used a 05-06 1000 top clamp, so I will have to drill the ignition/lock in order to properly fit it, as it's only hanging there with one bolt right now...

For now I used the 06-09 GSXR-600 clip-ons with matching MC. They are a little low and hit the fairing at full turn. Since this is a track bike, I could probably live with it for now...

I know that I can use TL1000s or CBR 929/954 clipons to fix this, but that will obviously require a longer brake line. What bike can I source a proper length brake line from that will work with the taller clip-ons and the 06-09 GSXR MC?

Thanks,
 
#317 ·
Finally got around to putting 08/09 GSXR600 forks on my 07 naked this weekend. Triples, forks, and wheel and rotors are on. Next on my list is brakes. I plan to use the GSXR master cylinder and calipers and the SV controls.

When removing the SV front brakes, I discovered a plug (I assume for the brake light, maybe?) running from the right side control cluster to the SV master cylinder. What exactly do I do with that plug when I end up installing the GSXR MC? Does the SV plug go into the GSXR MC directly? Do I need to swap the switch off the SV MC onto the GSXR MC?

Just did a search and came up with nothing. My bad if this has been covered before. I tried to troubleshoot this myself in the garage this weekend and ran out of daylight. It'd be nice to figure this out during the week so I can get back to it next weekend.
Any input would be awesome.

Thanks.
 
#323 · (Edited)
I have a 2006 SV650S. I'd like to make sure everything I'm considering putting together makes sense on paper before I decide on anything.

Here's what's going through my head right now:

04/05 GSXR 600/750 upper and lower triple
05/06 GSXR 1000 Forks
Black Tokicos
05/06 GSXR front axle
310mm rotor wheel

Edit: I misinterpreted a little of the information. I think I have it now.
 
#324 ·
I have a 2006 SV650S. I'd like to make sure everything I'm considering putting together makes sense on paper before I decide on anything.

Here's what's going through my head right now:

04/05 GSXR 600/750 upper and lower triple
05/06 GSXR 1000 Forks
Black Tokicos
310mm rotor wheel; Bore 100, PCD 120.

This would fit without any machining, right?
What wheel/axle are you planning to run? What is the rotor from?
 
#332 ·
oh sorry, 06 1000 forks. the forks will fit both combos, they're 50/54 and have a 30mm offset. so i'm just asking if there's any advantage to using a certain triple other than just the standard 06 1000 triples i guess. nevermind, i answered my own question haha thanks though!

i don't care about the ignition location or wheel lock bc it's coming off the bike anyway.
 
#337 ·
Man, I've tried to read this here and there...Don't want to clutter things up, but I came across a deal on a 2000 750 front end. Want to do this on my 03 S, but didn't see anyone here doing this conversion. Is the 00 front end doable? More trouble than it's worth, or just not popular swap? Thanks in advance for any help.
 
#339 ·
bolts up no problems, you even have steering lock. might have interference between clipons and fairing.
 
#340 ·
Hell yeah, thanks Junkie! I was thinking about aftermarket clipons to try to keep the riding position, would that help or would they need to be trimmed? I'm guessing you mean the ends of the GSXR clipons?
 
#341 ·
Okay, I've been looking through these fork swap threads long enough to make me confused. Can someone just look through this setup and tell me whether or not it will work together? I have a 1st Gen

05 GSXR 1000 Forks
05 GSXR 1000 calipers (black tokico)
05 GSXR 1000 Radial master cylinder
98 SRAD 750 front wheel
98 SRAD 750 rotors (320mm)
98 SRAD axle
SRAD upper and lower triples with a stem bearing replacement from TWF
5mm caliper spacers from TWF
SVS-model SS lines

From what I've read, everything should work together, but I guess I'm worried about the SRAD rotors working with the radial mc. If the SRAD rotors won't work, can I put a set of newer model rotors on the older SRAD wheel as long as they are the same bolt pattern and offset?

Also, will the SVS lines work with the radial mc and calipers? I was not entirely sure on this either.

Any help would be much appreciated.
 
#344 ·
From what I've read, everything should work together, but I guess I'm worried about the SRAD rotors working with the radial mc. If the SRAD rotors won't work, can I put a set of newer model rotors on the older SRAD wheel as long as they are the same bolt pattern and offset?

Also, will the SVS lines work with the radial mc and calipers? I was not entirely sure on this either.
That´s more or less the setup on my wife´s SV (except 04 GSX-R 600 fork legs and a R6 master cylinder). She has 95 triples, but they share the relevant dimensions with the SRAD ones (my setup is SRAD and 04 GSX-R 600 fork legs, rotors and calipers, therefore I know). Works without problems - not too sure about the brake lines, though, since she has a regular bar and aftermarket lines. My clipons aren´t OEM GSX-R as well.

One caveat: You have to space out the rotors by 2,5 mm on each side (I should even have the cnc programm lying around), since the SRAD triples are wider than the newer triples. Works without that as well, but barely so (rotors visibly off-center and nearly touching the caliper).

Ciao
Jan
 
#342 ·
I wouldn't mix the SRAD components with the 1000 parts. I can already tell you the 320mm rotors wont work with those calipers. You're better off trying to keep the stuff as close as possible and not venture too far away from compaitiblity, you could run into problems

The lines should work, but you might need to order different fittings. Length of the line is most important other than that
 
#345 ·
I wouldn't mix the SRAD components with the 1000 parts. I can already tell you the 320mm rotors wont work with those calipers.
They work with a simple 5mm spacer and he already adressed that (and better than me, I just used fitting brass washers).

You're better off trying to keep the stuff as close as possible and not venture too far away from compaitiblity, you could run into problems
It´s been done a lot already. For the 1st gen SV the SRAD triples, axle and wheel are the way to go regarding compatibility with steering stops and ignition lock (as long as you care about that).

Ciao
Jan
 
#346 ·
Awesome, thanks guys, thats what I needed to know. I found an awesome deal on an SRAD wheel with rotors and a (well used) tire that I wanted to pull the trigger on if it would work out. I didn't really want to use a newer model wheel because I'm not a fan of the mismatch wheel look and I have no real interest (or the funds) for a gsxr rear swap at this time. The rotors were what I was worried about the most.

If I was to get a set of SV1K rotors, would I still have the offset issues that Jan mentioned?