Hey guys,
So after enduring the monster's undersprung front forks for a while I decided to go forward with the GSXR swap. Hopefully this proves useful for at least one of you.
Parts List of specifically what I am using:
- 2008 gsxr 600 forks - there are many in varying condition available on ebay. I specifically went with 2008 gsxr 600 forks due to their stock spring rate and diameters. You can learn all the different options of what years are what sizes by reading this chart made by someone else:
http://i1076.photobucket.com/albums/w450/condershire/Fork-Conversion-Details.jpg - 2008 gsxr 600 front calipers - (ebay) - try and find ones that include the banjo bolts and caliper bolts to make things easier. I paid about $45 for mine to get some in decent shape.
- 5mm caliper spacer - I had these made by a friend for free, but if you don't mind paying $40 to have them nice and easy, here's another ebay link:
http://www.ebay.com/itm/271061115058?item=271061115058&viewitem=&sspagename=ADME:L:OC:US:3160&vxp=mtr- Gsxr caliper bolts. stock are long enough with the spacer. Many of the ebay ads come with these bolts, but in case they don't:
http://www.bikebandit.com/2008-suzuki-gsx-r600/o/m138935#sch554657- 5mm 6-bolt brake rotor spacer - these are installed between the wheel and brake rotor. Make sure you have Torx bits on hand for removing the rotors. You can get these made for cheap, but I found them nice and easy on ebay:
http://www.ebay.ca/itm/Brembo-type-6-bolt-5mm-disc-spacer-Yamaha-Ducati-Aprilia-Bimota-Benelli-Laverda-/350822155512?pt=UK_Motorcycle_Parts_13&hash=item51aea144f8&vxp=mtr- 2008 gsxr front axle (ebay) - buy one that includes the end nut.
- 0.5mm shims for the lower triple - GSXR fork is one mm smaller than the stock 696 at the lower triple, so add these shims to fill it out:
http://www.corse-dynamics.com/products/brake-suspension-components/lower-triple-clamp-conversion-shims/- Custom stainless brakelines from Magnum Shielding. The stock lines are too short due to the length of the gsxr forks, and the location of the banjo bolt on the gsxr calipers being in the centre as opposed to the top of the 696 brembos. These are DOT approved and can be sized to the length you need. These don't come with new crush washers so you'll need to pick up x7 of those somewhere else.
I ordered the 6' brakeline along with 1 35 degree 10mm banjos, and 3-pack of straight 10mm banjos (180 degree).
http://www.magnumshielding.com/store/byo-build-your-own-brake-lines.php- axle spacers - I had my friend make a 15mm spacer for either side. You can also cut the stock 696 spacer in half and add a 1mm shim on the left, or shim as necessary based on your cut.
A shot of most of the items ready to go:
and the caliper spacers:
Starting in on the swapFirst I propped up the front end of the bike using a hydraulic floor jack and propped up jackstands:
Ditched the fender. Hipster mode v1.0 enabled:
Dropped out the wheel, axle, and pulled the calipers off the forks:
After I detached the calipers, I loosened the triples and dropped out the first fork tube. Amputee mode v1.0 enabled:
Drop out the other fork. Legless!
Round the shims to the shape of the fork and bend the little tabs over and slide them into place in the bottom triples. Carefully slide the gsxr forks into place and rough them into place. Your front end WILL be higher than stock. There's no way around that. You can slide the forks up as far as you can, but you will reach a limitation at the top where the fork briefly goes thinner, but you can't clamp onto that part.
I forgot to take pictures of installing the rotor spacers, but it's straight forward - they are between the wheel and the rotor.
Install the wheel, using the GSXR axle. You will need to install the two 15mm spacers on either side of the wheel at this point as well. Make sure the wheel is centered before tightening down the pinchbolts:
Brake calipers installed, you can see the 5mm spacers between the caliper and fork:
Installed the new brakelines after cutting them to length. Don't forget to leave a little slack for the shock rebound. The brakelines will come with instructions on how to build them so I won't go into detail on that.
And that's pretty much it! Bleed the brakes, take 'er for a rip, you're done!
Forgot to mention, you'll also need to sort out something around a bracket/spacer for mounting the fender. You're on your own for this as I haven't got mine made yet. I just attached the fender at only the bottom hole.
Feel free to ask any questions and I'll do my best to answer.
