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Discussion Starter · #1 ·
So I'm going to make a step by step picture catalog/guide on doing a GSXR swap for a 99-02 SV650. Things should start to come up very soon. I will begin to post as soon as I have the stock front end off. Suscribe if you would like to see it as it goes...
 

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Discussion Starter · #2 ·
First you gotta go and get yourself a 99-02 SV650 and get it into your workspace..


Since my garage door doesnt shut and it is currently 1 degree here in WI mine just happens to double as my living room.

Now before I go on I strongly suggest you invest in some baggies and a permanent marker so that you can label things as you take them apart.

The parts list is as follows...

2006/07 GSXR 750 front forks.
2006 GSXR wheel and calipers.
1997 SRAD 750 upper/lower triples.
TWF top bearing kit.
lots and lots of fasteners...



So start by getting the bike up with a rear jackstand and secured in the front with a regular jack but don't jack it up yet. You'll need to do a lot of torquing on some nuts, especially the ones for the handlebars and the bike isnt very stable once it's been lifted.


So start by undoing the headlight bolts, 2 on each side and a third on the bottom.
For some reason i dont have a pic of this, but its pretty self explanatory.

Then undo the controls, the left has 2 and the right has 3 screws.


There are also 2 screws to remove the left mirror along with the master cylinder. They come out with an 8mm socket. The right one will have to be slid off after the grip is removed.

Ok so now its time to get the handlebars off...

The 4 chrome things on top of the risers can be removed using a razor blade but be careful not to scratch them.




This bolt sucks...you really need a lot of leverage to get it off so its a good idea to like slide a pipe on the end of the wrench. This is the bolt that holds the lower part of the riser in place.



After you get that off the triple should look something like this...



The next thing is to remove the gauges which you can also see in the above pic. All it takes is some more finesse..It has 2 bolts that are located ahead of the 2 that keep the risers on.



Lookin good...So now you gotta take off the top nut. Be careful not to lose the washer that is under it. Also, you will need an allen wrench to remove the upper pinch bolts.
After that it slides right off.

Makes you wonder why people on ebay always say "damage from where triples clamp". If I can do this without damaging it, anyone should be able to.

And the bottom of the triple clamp. In this pic the upper holes are for the speedo and the lower ones are for the risers.




Ok now you can jack the bike up. I would suggest only getting it off the ground far enough so that the tire can clear the ground. It's also a good idea to put jackstands under the pegs for added stability.
The wheel comes off relatively easy. Just unscrew the axle and it comes out as a whole. Watch for the speedo sensor on the left side, it's crammed in between the fork and the wheel on the left side. Also, you will have to remove at least one of the calipers for clearance.




So this is kinda what it will look like:
 

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The parts list is as follows...

2006/07 GSXR 750 front forks.
2006 GSXR wheel and calipers.
1997 SRAD 750 upper/lower triples.
This is gonna be interesting. The SRAD triples are wider than later makes, making alignment of the rotors and radial calipers a bit tricky with the (slimmer) wheels from 00 up. What are you gonna do about that? What axle will you use?

Looking forward to your further progess!

Ciao
Jan, SRAD triples, SRAD wheel, SRAD axle, 04 rest => shimmed rotors
 

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This is gonna be interesting. The SRAD triples are wider than later makes, making alignment of the rotors and radial calipers a bit tricky with the (slimmer) wheels from 00 up. What are you gonna do about that? What axle will you use?

Looking forward to your further progess!

Ciao
Jan, SRAD triples, SRAD wheel, SRAD axle, 04 rest => shimmed rotors

+1 shimming will be required i run srad triples and axle with busa rim and 05 gsxr 600 forks, you need a 2 to 2.5 mm shim between the rim and rotors for the calipers to line up correctly
 

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+1 shimming will be required i run srad triples and axle with busa rim and 05 gsxr 600 forks, you need a 2 to 2.5 mm shim between the rim and rotors for the calipers to line up correctly
Furthermore he´ll need a way to center the wheel - it´s a tad slimmer than the wheels we use. I´m curious what he comes up with, especially since I know very little about the changed axle design from 06 up...

Ciao
Jan
 

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Those appear to be 600 forks I think? Haven't seen any gold 750 ones, they are usually black on the 750?

You will also need shims between those fork legs & lower triple clamp - the SRAD is for 54mm legs, those Showa 06+ forks are 53mm. So you will need some 0.5mm (~20thou) shim material to make a sleeve.

It will indeed need the 3.5mm rotor shims (2.5mm for a TL/busa wheel) and the wheel will also need to be offset by 3.5mm on the axle. Stock spacer on right side of axle is 12.25mm - should be 14.75mm to recenter wheel.
So can make a new one-piece spacer or add 3.5mm shim stack between right spacer & right fork leg.

An 08 Hyabusa axle will account for the extra width required (forkspacing will be 7mm wider using those SRAD triples)
 

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Those appear to be 600 forks I think? Haven't seen any gold 750 ones, they are usually black on the 750?

You will also need shims between those fork legs & lower triple clamp - the SRAD is for 54mm legs, those Showa 06+ forks are 53mm. So you will need some 0.5mm (~20thou) shim material to make a sleeve.

It will indeed need the 3.5mm rotor shims (2.5mm for a TL/busa wheel) and the wheel will also need to be offset by 3.5mm on the axle. Stock spacer on right side of axle is 12.25mm - should be 14.75mm to recenter wheel.

An 08 Hyabusa axle will account for the extra width required (forkspacing will be 7mm wider using those SRAD triples)

i believe those are 04/05 600/750 forks but the glare might be throwing me off a bit
 

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i believe those are 04/05 600/750 forks ...
Later Axle tells they are definitely the 06+ forks - gold are more likely the 600's however.
In fact the fiche does not show an alternative colour so have to be the 600's.

I see on EBay all the time they are listed by sellers as 600/750 - they are the same fitment however, but the 750's (black outer tubes) have stiffer springs (1kg vs 0.9) - dampers are identical.
 

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Everyone has their own way of doing things so this isn't criticism just alternative:

After removing the riser tops & bars, drop the speedo, then undo the top clamp & flip it over & stick it back on the forks to get easier access to the riser nuts & ignition bolts (unplug ignition harness if it helps to get extra freedom)
No need to re-clamp it up, just use the forks to hold it from turning.
 

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Everyone has their own way of doing things so this isn't criticism just alternative:

After removing the riser tops & bars, drop the speedo, then undo the top clamp & flip it over & stick it back on the forks to get easier access to the riser nuts & ignition bolts (unplug ignition harness if it helps to get extra freedom)
No need to re-clamp it up, just use the forks to hold it from turning.
That's exactly what I did when I was forced to drill out the security torx screws in the bottom of the ignition. Worked like a charm.
 

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Discussion Starter · #12 ·
That stupid "tamper proof" torx thing was a pain. Had to go to 3 sears stores before i found one that worked. As D'Ecosse said, several people post up on ebay 600/750 so I just used 750 when i was describing them.

Even after reading the "swap post" that is around here somewhere I must have missed the part that the SRAD triples were wider than later models. Thanks a lot for the shim sizes for the rotors and wheel, saved me a TON of time...
 

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Discussion Starter · #13 ·
Ok, so now you gotta use a size 40 or 45 (40 worked for me but it seemed small) tamper proof torx wrench to get the ignition out of the triple.

After that, unscrew the retaining bolts that hold the speedo cable in place




Then you can snake it up and out of the way of the triples. Be sure to double check that the forks and the brakes and brake lever are completely cleared of all wires and harnesses, whatever.

Also, slide off the blinker and headlight retainers.


Now it's time to pull the forks. Get a rag, unless you don't care about your stock parts, and cover the nut that has like 5 divots in it and lightly tap it with a screwdriver and a hammer until you can feel it get loose enough that you can use your hands. Then, hold the forks from the bottom triple and unscrew the nut. This is the ONLY thing holding the forks up now so be careful.



And here's the stock front end, removed from the bike.

So here's your bike after the front end is gone. Try riding it...


Next, remove the screws that hold on the headlight and look for the 2 bolts that fell into the housing when you originally took off the headlight. Then undo the wires for the blinkers since you can't really use them right now. Also be sure to put some tape over the wires and label them so you know right from left.



Phew! Easy huh? Now you can put your new forks on...or at least see what they look like on the bike.

 

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... What do you suggest as shim material? Thin sheet of aluminum?
I assume you mean for the fork legs in the triple clamp?

It is specifically designated as shim stock - ideally 0.5mm but if you can't find metric 20 thou" will be good enough. Can be whatever you can find - brass is common.
If you can't find shim stock consider this
http://www.convertibars.com/Accessories.cfm - click on the link for additional completion components near the bottom - that is a kit with pre-formed shims. Those are actually 1mm & 2mm (that is the diameter delta designation - actually 0.5mm & 1mm stock) and intended to reduce 53mm to 52 or 51. But these are very close to the 54 you need and will re-form to that very small change on overall diameter.
 

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For the wheels/rotors
Those are going to be some thick spacers - best machined as a one-piece
(I thought someone had done these at one time?) .

Here's what I did temporarily on my Triumph GSXR conversion



Then the final spacers were made



Note that these are only 1.5mm spacers - you will need 3.5mm (1/8" will get you close enough if can't find metric plate)
 

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For the wheels/rotors
Those are going to be some thick spacers - best machined as a one-piece
(I thought someone had done these at one time?) .

Here's what I did temporarily on my Triumph GSXR conversion



Then the final spacers were made



Note that these are only 1.5mm spacers - you will need 3.5mm (1/8" will get you close enough if can't find metric plate)
+1 i have these same spacers but mine are 2.5mm thick
heres a blueprint provided to me by someone on here can't remember who though sorry
I simply brought it to a machine shop and they hooked me up cost 30 bucks for both i think
 

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You have a 'Busa rim though redmonkey - that is NOT the layout for the GSXR wheel the OP is using

Using your drawing above:
ID = 100.2
PCD = 120mm - 5 x 10.5 x 72deg
OD = (ideally whatever OD of wheel hub is) - something around 140mm

Thickness - 3.5mm (1/8" would be OK)
 
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