S2R800 Fork Dilemma

[Artful]

Advice on rotor spacers that directly solve the OP's dilemma is not useful?

ooooorrrrrrrrrrr a joke about bent forks. You make the call 

[corey]

... do you happen to have a motivational poster about comprehension of motivational posters that will make me feel even DUMBER?

where's that "shoot self in face" emoticon when you need it... 

[TitanMonsterS4R]

that's just wrong on soo many accounts!

[Artful]

... do you happen to have a motivational poster about comprehension of motivational posters that will make me feel even DUMBER?

where's that "shoot self in face" emoticon when you need it... 

[TitanMonsterS4R]

Okay let's all relax.
I have 999 forks on my S2R800, and they will fit. Your forks are not bent.
You need four very simple spacers made, all exactly the same, as well as 4 new bolts for your calipers that are a bit longer.
I don't have the exact specs on the spacers right now, but i can give you the gist. They are 5mm thick (as the rotor spacing on the 999 is 5mm more than our monsters, thus you need to move your caliper 5mm closer to the rotor)... The outer diameter of the spacer is something similar to the mounting area of the caliper/fork bottom.. it's somewhere between 3/4" to 1" or a bit larger (i think my machinist actually used stock 1-1/8th" steel rod... the outer diameter really isn't all that important)... the Inner diameter is the same as the bolt hole for your calipers. You just stick these four little rings between your calipers and their mounting points on the fork bottoms. It's basically just a 5mm thick washer.

Now i know everyone is going to freak out... OMG it's your brakes, spacers are soooo dangerous... It's 5mm guys. It works perfectly. I used steel for my spacers, and bought 316 hardened stainless bolts from Pro-bolt to complete the kit.

You also want to use your STOCK axle (drill holes in it if you want for the bottom adjusters), as the spacing on a 999 axle is incorrect for the monster. ask me how i know.

Everyone can chime in as necessary, but this is how it worked on my S2R800. It fits, i have ZERO issues after 4000 miles.

999 forks.
53mm bored top triple.
53mm shimmed bottom triple.
5mm spacers for calipers.
Longer bolts to accommodate caliper spacers.

Any machine shop should be able to make those spacers for you on the cheap.
As berg said, if you have a 999 wheel with 999 rotors on it, it should bolt right on, aside from the fact that you'd need new calipers to accommodate the 320mm rotors, as your stock S2R800 rotors are only 300mm.

hopefully this helps, feel free to PM me if you need any guidance on the swap.

Thanks Corey -

Yesterday we were able to accomplish:
Drilling the holes in my stock S2R axle
Creating the spacers for the Brembo goldline brake calipers
Mounted the triples
Shortened the caliper bolts

The new 999 forks will arrive tomorrow.  So we just have to mount those and get the caliper spacing right and then install the 53mm clip-ons.  It all sounds so simple after all our tribulations.  Let's hope we get it completed so I can enjoy the few remaining sunny days here in DC.