Gitzy
30-08-2011, 08:26 PM
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 as well as provide information for anyone wanting it about these forks.
Let's start with the matrices for the dimensions of the various fork models:
http://i1136.photobucket.com/albums/n487/gitzy841/GSXR%20Fork-Caliper%20Info/Fork-Conversion-Details.jpg
http://i1136.photobucket.com/albums/n487/gitzy841/GSXR%20Fork-Caliper%20Info/GSXR-Fork-Diagram-1.gif
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 for this post.
Forks
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, 25mm bore
http://i1136.photobucket.com/albums/n487/gitzy841/GSXR%20Fork-Caliper%20Info/03-04_1000.jpg
2005/06 1000
Bronze/black inners; black calipers
310mm rotors
950 springs
30mm offset, 54mm lower clamp
Center ignition top clamp, 28mm bore
http://i1136.photobucket.com/albums/n487/gitzy841/GSXR%20Fork-Caliper%20Info/05-06_1000.jpg
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
http://i1136.photobucket.com/albums/n487/gitzy841/GSXR%20Fork-Caliper%20Info/04-05_600-750.jpg
2006+ 600
gold/ chrome leg, black calipers
310mm rotors
900 springs
30mm offset, 53mm lower clamp
Left offset ignition top clamp, 28mm bore
http://i1136.photobucket.com/albums/n487/gitzy841/GSXR%20Fork-Caliper%20Info/06_600.jpg
2006+ 750
black/ bronze leg
310mm rotors
1000 springs
30mm offset, 53mm lower clamp
Left offset ignition top clamp, 28mm bore
http://i1136.photobucket.com/albums/n487/gitzy841/GSXR%20Fork-Caliper%20Info/07_750.jpg
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
Not interchangeable re pads however
http://i1136.photobucket.com/albums/n487/gitzy841/GSXR%20Fork-Caliper%20Info/03-05_300_caliper.jpg
All other GSXR models
http://i1136.photobucket.com/albums/n487/gitzy841/GSXR%20Fork-Caliper%20Info/05_310_caliper.jpg
Yamaha Monoblock (R6)
http://i1136.photobucket.com/albums/n487/gitzy841/GSXR%20Fork-Caliper%20Info/R6_caliper.jpg
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
http://i1136.photobucket.com/albums/n487/gitzy841/GSXR%20Fork-Caliper%20Info/Fork_Caliper_spacer_matrix.jpg
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 front of the speedo for naked)
It has 30mm offset and 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 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 it with wheel straight ahead, as opposed to 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 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 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.
http://i1136.photobucket.com/albums/n487/gitzy841/GSXR%20Fork-Caliper%20Info/Early_axle.jpg
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 wheel & right fork leg.
http://i1136.photobucket.com/albums/n487/gitzy841/GSXR%20Fork-Caliper%20Info/late_axle.jpg
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 size also
Gen 1 SV650 is same bottom bearing but requires 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
http://i1136.photobucket.com/albums/n487/gitzy841/GSXR%20Fork-Caliper%20Info/Rotor_Matrix.jpg
Mix n Match Capability for Wheels/Rotors:
01-04 1000 and 01-05 600/750 and SV1K all are 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 wheel only.
09+ 1000 and 08+ 600/750 take 310mm rotors only - note that these rotors are NOT compatible with group immediately above & vice versa.
This info was composed by D'Ecosse of SVRider/TLplanet
Hopefully this will concentrate all the dimensional information on the most popular SV/GSXR fork conversion possible configurations as well as provide information for anyone wanting it about these forks.
Let's start with the matrices for the dimensions of the various fork models:
http://i1136.photobucket.com/albums/n487/gitzy841/GSXR%20Fork-Caliper%20Info/Fork-Conversion-Details.jpg
http://i1136.photobucket.com/albums/n487/gitzy841/GSXR%20Fork-Caliper%20Info/GSXR-Fork-Diagram-1.gif
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 for this post.
Forks
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, 25mm bore
http://i1136.photobucket.com/albums/n487/gitzy841/GSXR%20Fork-Caliper%20Info/03-04_1000.jpg
2005/06 1000
Bronze/black inners; black calipers
310mm rotors
950 springs
30mm offset, 54mm lower clamp
Center ignition top clamp, 28mm bore
http://i1136.photobucket.com/albums/n487/gitzy841/GSXR%20Fork-Caliper%20Info/05-06_1000.jpg
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
http://i1136.photobucket.com/albums/n487/gitzy841/GSXR%20Fork-Caliper%20Info/04-05_600-750.jpg
2006+ 600
gold/ chrome leg, black calipers
310mm rotors
900 springs
30mm offset, 53mm lower clamp
Left offset ignition top clamp, 28mm bore
http://i1136.photobucket.com/albums/n487/gitzy841/GSXR%20Fork-Caliper%20Info/06_600.jpg
2006+ 750
black/ bronze leg
310mm rotors
1000 springs
30mm offset, 53mm lower clamp
Left offset ignition top clamp, 28mm bore
http://i1136.photobucket.com/albums/n487/gitzy841/GSXR%20Fork-Caliper%20Info/07_750.jpg
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
Not interchangeable re pads however
http://i1136.photobucket.com/albums/n487/gitzy841/GSXR%20Fork-Caliper%20Info/03-05_300_caliper.jpg
All other GSXR models
http://i1136.photobucket.com/albums/n487/gitzy841/GSXR%20Fork-Caliper%20Info/05_310_caliper.jpg
Yamaha Monoblock (R6)
http://i1136.photobucket.com/albums/n487/gitzy841/GSXR%20Fork-Caliper%20Info/R6_caliper.jpg
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
http://i1136.photobucket.com/albums/n487/gitzy841/GSXR%20Fork-Caliper%20Info/Fork_Caliper_spacer_matrix.jpg
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 front of the speedo for naked)
It has 30mm offset and 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 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 it with wheel straight ahead, as opposed to 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 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 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.
http://i1136.photobucket.com/albums/n487/gitzy841/GSXR%20Fork-Caliper%20Info/Early_axle.jpg
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 wheel & right fork leg.
http://i1136.photobucket.com/albums/n487/gitzy841/GSXR%20Fork-Caliper%20Info/late_axle.jpg
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 size also
Gen 1 SV650 is same bottom bearing but requires 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
http://i1136.photobucket.com/albums/n487/gitzy841/GSXR%20Fork-Caliper%20Info/Rotor_Matrix.jpg
Mix n Match Capability for Wheels/Rotors:
01-04 1000 and 01-05 600/750 and SV1K all are 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 wheel only.
09+ 1000 and 08+ 600/750 take 310mm rotors only - note that these rotors are NOT compatible with group immediately above & vice versa.
This info was composed by D'Ecosse of SVRider/TLplanet