forks

[Barra58]

Anyone got any suggestions for usd forks that might fit into the GPz 84 model not opposed to making new triple clamps to suit but don't want to go mad and buy the $2000 + ohlins

[Gitzy]

Anything Modern will look the part..

http://www.ebay.com/itm/ZX6-Front-End-Suspension-Forks-09-10-11-12-Kawasaki-Ninja-ZX6R-/261741272936?pt=Motorcycles_Parts_Accessories&fits=Make%3AKawasaki&hash=item3cf0fedf68&vxp=mtr

[Barra58]

Thanks bloke, much appreciated

[Gix11]

Yep, as Gitzy said mate. Once you get them it's just a case of sorting your stem out.

[Barra58]

Sounds good, hopefully will be soonish, things are pretty tight at the mo, I'm one of them lucky miner blokes that just recently got pay cuts an shit. Also trying to sell pre loved car bits but everybody else up here in same boat, with no disposable income.

[Barra58]

G'day all, another question, as you guys may have seen I got a set of 2003 ZX6R usd forks, now for you engineering guys, would it be ok to turn the head stem from 35 mm dia. down to 28 mm dia. or is better to get some 6061 round stock and make a complete new one?

Cheers,
laurie

[ozzy1100]

G'day all, another question, as you guys may have seen I got a set of 2003 ZX6R usd forks, now for you engineering guys, would it be ok to turn the head stem from 35 mm dia. down to 28 mm dia. or is better to get some 6061 round stock and make a complete new one?

Cheers,
laurie
Need pictures on that one... Depends what is left of wall thickness etc and to turn a new one I only ever use 7075 t651

[Barra58]

Thanks OZZY, here is some pics, and yeah if turned down would only have 6 mm side wall thickness, um last pick is sort of what id need, with a 28 mm x i'm guessing .5 mm pitch would have to measure though and the other thread is 25 mm by same pitch, if you give me a ball park price + freight to Bowen, 4805, would be great, email is laurie_wyngaard@bigpond.com, and if your happy to do this i'll get you some better dimensions. I'd do it myself but to hard to get the ally up here and having to use other persons machine plus the get someone else to cut thread because the lathe I have access to is 50 years old!

http://i1006.photobucket.com/albums/af190/Truck58/GPz%20750/th_IMG_0796_zpskslprtor.jpg (http://s1006.photobucket.com/user/Truck58/media/GPz%20750/IMG_0796_zpskslprtor.jpg.html)

http://i1006.photobucket.com/albums/af190/Truck58/GPz%20750/th_IMG_0797_zpsn2xsqazj.jpg (http://s1006.photobucket.com/user/Truck58/media/GPz%20750/IMG_0797_zpsn2xsqazj.jpg.html)

http://i1006.photobucket.com/albums/af190/Truck58/GPz%20750/th_IMG_0799_zps9rmkgiqg.jpg (http://s1006.photobucket.com/user/Truck58/media/GPz%20750/IMG_0799_zps9rmkgiqg.jpg.html)

http://i1006.photobucket.com/albums/af190/Truck58/GPz%20750/th_IMG_0800_zpsqn6qxarl.jpg (http://s1006.photobucket.com/user/Truck58/media/GPz%20750/IMG_0800_zpsqn6qxarl.jpg.html)

http://i1006.photobucket.com/albums/af190/Truck58/GPz%20750/th_IMG_0798_zpspilfaesh.jpg (http://s1006.photobucket.com/user/Truck58/media/GPz%20750/IMG_0798_zpspilfaesh.jpg.html)

[Barra58]

oh and thread pitch is 0.75 mm not 0.5 mm as that was a by eye guess.

[ozzy1100]

I don't think you want to pay what I'll charge you mate (400ish 50 of that just material with out postage)
Why don't you look at using the stem out off the original with bushes and bosses some times that is feasible
There are a few ways to go it, norm takes me a hr just to draw up what is needed for a new stem and that's with both old and new stem and new yokes in front of me.....
Trust me take your time and look at it from a few angles

[ozzy1100]

Wait to you finish it and remember u need to do something with stealing stops....

[ozzy1100]

6 mm wall is almost ok btw but have you thought of opening up the yoke instead,

[Barra58]

yeah have thought about that, but removing, cutting & shutting, dunno, might have a bit more of a think about it, think outside the square. and yeah re using the old stem was my original plan, may go back to that, was just that it's an old heavy pos, but it will be easy to make a boss to go into the bottom clamp, don't have a top clamp yet going to get a bloke in Mackay to machine it up. and the old lathe will be ok for that part of it.

[bluedrags]

Any more done with your forks as I'm having a similar problem and would be good to see how you go?.

[Barra58]

^^^ Yeah Bud, I ended up using the original gpz750 stem and machined a boss to press onto the stem then machined again to the correct press fit diameter and pressed it into the lower triple clamp, however when I get a lathe in the near future I will machine one out of ally which hopefully will be much better, followed the advise from ozzy :)

[Barra58]

Sorry guy's, got another question, probs will have many more before this pos is finished, anyway I bought a rear zx6r rear wheel and you guessed it, so does anyone know what swingarm will fit without to many mods preferably from the zx range of kwaka's.
Thanks in advance

[bluedrags]

I have parts off a 96 zx6r if that's any good to you.

[Barra58]

Swingarm with rear axle and swingarm axle/pivot, price and it would have to be freighted to 4805, Bowen, Qld so I guess some sort of guestimate on freight price as well

[bluedrags]

I have complete shock if interested in that as well but no back axle.

[Boogieman]

You're probabl past this point but aren't modern USD's a bit short to replace 80's forks?
I'm used to Suzuki. Is kwaka different?

[ozzy1100]

No diffrent but there is more than fork length at play
Diffrent aspect of tyre's, stiffer springs with shorter action etc
Diffrent rake if you change frame angle...
There are a few good ways the lengthen forks if you need them
or want std looking ride hight

[Tony Nitrous]

Stepped top yoke work well and are quite common.
Thread in extensions are do-able as the bottom yoke does more of the work than the top,
I have seen internal extensions done but not had much to do with them,
I think Ben had a clip showing him doing them.

I'm looking at a front end swap but it must be radial braked.
Not worth the effort to end up with more shitty 6-pots off another Busa.

[Tony Nitrous]

Just ran a tape down a few here, Fork top to spindle.
Very rough measure, some on stands, some not,
but a common sort of average between USD and Non-USD

Traditional / old style / non-USD..
GSX1400........... 780mm
Bandit 1200 ...... 770mm
GSX1100ET ..... 770mm
GSXR1100G .... 770mm

My two USD front ends...
Gen-1 Hayabusa... 695mm
B-King................... 685mm

[Boogieman]

Yeah that's what I'm getting at.
A good swap is the '92 ish GSXR range as they're USD but long to suit the old school frame but as You've pointed out, the best you can do is a shitty (?) set of 6 pots!
That was a bit of sarcasm as I thought 6 pots were pretty bloody good. Are radial mounted callipers that much better? ( not sarcasm, serious question)

[Tony Nitrous]

My Busa has a OK condition set of 6 pots and original master,
braided lines, quality fluid and pads. All serviced and spot on.

My B-King has 7 year old stock radial brakes,
Original fluid, pads and factory rubber lines.

B-King is in a different league!

GSX1400 has similar 6 pots to my Busa,
and in good condition they are best described as "average".

King is two finger braking, even at speed, I love radials.
Funny, I know Busa and GSX14 owners who bin the 6-plops
to fit SV or similar 4 pots. Suzuki 6-Plops are over rated.

[Boogieman]

I must be missing out as a mate has '01 6 pots on his Kat and they are phenomenal compared to my old Slabby GSXR
Maybe time to work out an upgrade.

[Barra58]

You're probabl past this point but aren't modern USD's a bit short to replace 80's forks?
I'm used to Suzuki. Is kwaka different?

Yeah, bit past, however I did measure the fully extended length and was only around 30mm difference from memory

[Gix11]

If you get stuck, there's these as Tony mentioned:

http://www.store.extremecreations.com.au/fork-extensions

[Barra58]

Yes, was checking them out the other day, awesome bit of gear and look relatively easy to install.

[slingy88]

Ok, here's some data, not sure how accurate it all is but probably a good guide for starters. Copy and paste some where safe
Make/Model year Range Fork Length mm (inch) (axle center to fork cap top extended suspension)
Buell
M1 700mm (27,5'')
M2 730mm (28,75'')

Ducati
998s ohlins 720mm (28,374'')
monster 750ie 02 730mm (28,74'')
st3 04-05 725mm (28,54'')
st4s 02-03 697mm (27,44'')

Harley Davidson
most 812mm (32'')

Honda
CBR1000RR 692mm (27,25'')
CBR600F1 87-90 738mm (29,05'')
CBR929 00-01 724mm (28,5'')
CBR954 02-05 724mm (28,5'')
RC51 SP1 762MM (30'')
RC51 SP2 736MM (28,97'')
vfr 750 fl 791mm (31,15'')
VFR800 780mm (30,75'')
vtr1000f 778mm (30,62'')

kawasaki
fz1 2007 762mm (30'')
versys 774mm (30'')
ZRX1100 766mm (30,15'')
ZX10R 06-07 743mm (29,25'')
ZX10R 04-05 730mm (28,75'')
ZX14 742mm (29,25'')
ZX636 750mm (29,5'')
ZX9r B4 94-97 766mm (30,15'')

Suzuki
GSF 400 JDM 820mm (32'')
GSXR1000 01-02 726mm (28,54'') was also quoted 715mm ?
GSXR1000 03-04 720mm (28,34'')
GSXR1000 05-06 720mm (28,34'')
GSXR1000 07-08 720mm (28,34'')
GSXR1100W 94 770mm mm (30,25)
Gsxr1300 Hayabusa 99-07 725mm (28,54'')
Gsxr1300 Hayabusa 08
GSXR600 00-03
GSXR600 04-05 720mm (28,34'')
GSXR600 06-07 738mm (29,05'')
GSXR750 88-89 43mm RWU 730mm
GSXR750 90-95 750mm (29,5'') 257mm (10 1/8'')
GSXR750 00-03
GSXR750 04-05 720mm (28,34'')
GSXR750 06-07 738mm (29,05'')
GSXR750 SRAD 96-99 730mm (28,75'')
RF600 97 750mm (29,5'') 257mm (10 1/8'')
TL1000R all 717mm (28,22'')
TL1000S all 732mm (28,81'')
VZ800 Marauder 838mm (33'')

Yamaha
FZR400 790mm(31.1'')
FZ750 1986 825mm (32,5'')
FZR1000 87-88 770mm (30,3'')
FZR1000 exup 89 770mm (30,25'')
XV920 J virago 82-83 825mm (32,5'')


As can be seen the kwaka USD hits the mark best with the ZX14 and 636 being the most favourable. They are both pretty cheap on the bay as well. dont seem as popular as other stuff for some reason. My choice would be the ZX14 forks. Longest of the usd's and once they stay parallel where you would want to clamp headlight mounts on. The 636 forks sort of waiste in between the tripples making it a bit more awkward to mount stuff. Both look good and are radial front ends too.

Cheers Slingy

[slingy88]

Ok, i new i had some more data some where. I think came from the TL Forum, so big thanks to them .

Lots of very usefull numbers.

http://i557.photobucket.com/albums/ss11/slingy88/GSXR%20Turbo/Fork_Conversion_Details_1_2_zpsolaznvpx.jpg (http://s557.photobucket.com/user/slingy88/media/GSXR%20Turbo/Fork_Conversion_Details_1_2_zpsolaznvpx.jpg.html)

[Barra58]

Cheers Slingy, good info, looks like I got a little bit of luck with the forks then, they are the 636 units!

[slingy88]

Yep, you did good ;-)

[Tony Nitrous]

I'd consider a radial font end a MUST for a swap.
Why bother doing it all for something as dated as an early Busa.

The next level up the ladder (and what I'd like)
are the current "Big Piston" forks.
I'm hearing good things about the current ones...

http://s13.postimg.org/unprkujd3/image.jpg (http://postimage.org/)

[Barra58]

G'day all, so another question, do you guys use the boots that go over the choke valves on the old carby donks or just don't bother, can get them from the States for 44 USD. but the friggen freight is the same price, they probably weigh about a gram each so pisses me right off to pay that sort of freight when they'll probably put them in an envelope that cost at the most 10 bux

[slingy88]

Is this through Alphasport or Partshark or similar?
Even if it isn't, look up the part on the above site's, as even if the original part is no longer available, it will nearly always list a current part substitute. Then go into your local dealer /shop and ask for a price on that part number. You might be surprised.
I was trying to get some slingshot carb parts and told they were obsolete. Went on Alphasport and it went through 5 different links untill it settled on a current part substitute. Went back in to the same shop with that part number and got told," have em tomorrow " and when they turned up they looked identical to the original part. The point I am trying to make is part numbers change alot more frequently than the parts!

[Barra58]

Cheers for that, I'll give it a go, and yeah all I did was type in the part #, will have to talk to the Mackay or Townsville suppliers.