Deano
30-01-2010, 08:07 PM
How To. K4/K5 front end onto early gsxr.
First of all you need to obtain yourself a new front end in this example I have a K5 GSXR 600/750 complete front end.
http://www.asfphotos.com/upload/1264881098.jpg
I have preformed this conversion before by swaping over the steering stems but this is not always able to be done as the diameters of the steering stems where they press into the bottom clamp can differ causing problems if wanting to go the stem swap way. In this case I am wanting to use the original k5 steering stem and triple clamp set.
First you need to get yourself either the standard early or late bottom headstem bearing. These bearings are both the same size. if you have neither or just want to put in a new bearing (preffered option) then your local bearing company can help you out. The part no you need is 32006JRRS. The JRRS in the part number means it has a seal attached to the bottom of the bearing. YOU NEED THIS don't bother trying to reuse the old seal buy hammering it into shape and then buying the cheaper bearing without the seal. It just isn't worth it.
While you are at your bearings supplier you need to get the top bearing. The bearing is a HR32906J. NSK are about the only manufacture that makes this beairngs now and they are extremely hard to come across. Your bearing supplier will probably tell you they are not made any more if so they are not looking hard enough. If you have a problem then contact me cause I work in a bearing shop and can get these bearings for you. don't pay anymore than about $85 for this bearing, Yes it is expensive but you will just have to deal with it.
Once you have your 2 bearings you are set to start work. After disassembly of the standard front end you will need to punch out the cups from the old beairngs and press in the new bearing cups into the headstem.
http://www.asfphotos.com/upload/1264889574.jpg
TIP: cut out 2 little half moons from the step in the top of the headstem as this will then allow removal of the bearing cup in years to come.
After the bearng installation you will need to call on your friendly machinest/engineer to machine up the nut that holds it all together.
The pic shows the nuts in question.. the nut on the right is the early gsxr stepped nut, the middle one is the standard k5 nut before machining and the nut on the left is the machined nut ready for assembly
By machining the nut in this way this will allow you to use the standard early headstem seal. you will notice the the later seal is smaller in diameter than the older seal.
http://www.asfphotos.com/upload/1264886476.jpg
Once the nut is machined to suit the inside of the seal (33.9mm) you just assemble the triple clamp set as per normal using all the standard late model parts.
http://www.asfphotos.com/upload/1264882002.jpg
Then it is just a matter of doing something fancy with the steering stops and it is just about done.
this info is relevant for SRAD and newer front ends (unsure about k5 gsxr1000 and newer) going into slingshot gsxr750/1100 and watercooled gsxr750/1100 up to SRAD.
First of all you need to obtain yourself a new front end in this example I have a K5 GSXR 600/750 complete front end.
http://www.asfphotos.com/upload/1264881098.jpg
I have preformed this conversion before by swaping over the steering stems but this is not always able to be done as the diameters of the steering stems where they press into the bottom clamp can differ causing problems if wanting to go the stem swap way. In this case I am wanting to use the original k5 steering stem and triple clamp set.
First you need to get yourself either the standard early or late bottom headstem bearing. These bearings are both the same size. if you have neither or just want to put in a new bearing (preffered option) then your local bearing company can help you out. The part no you need is 32006JRRS. The JRRS in the part number means it has a seal attached to the bottom of the bearing. YOU NEED THIS don't bother trying to reuse the old seal buy hammering it into shape and then buying the cheaper bearing without the seal. It just isn't worth it.
While you are at your bearings supplier you need to get the top bearing. The bearing is a HR32906J. NSK are about the only manufacture that makes this beairngs now and they are extremely hard to come across. Your bearing supplier will probably tell you they are not made any more if so they are not looking hard enough. If you have a problem then contact me cause I work in a bearing shop and can get these bearings for you. don't pay anymore than about $85 for this bearing, Yes it is expensive but you will just have to deal with it.
Once you have your 2 bearings you are set to start work. After disassembly of the standard front end you will need to punch out the cups from the old beairngs and press in the new bearing cups into the headstem.
http://www.asfphotos.com/upload/1264889574.jpg
TIP: cut out 2 little half moons from the step in the top of the headstem as this will then allow removal of the bearing cup in years to come.
After the bearng installation you will need to call on your friendly machinest/engineer to machine up the nut that holds it all together.
The pic shows the nuts in question.. the nut on the right is the early gsxr stepped nut, the middle one is the standard k5 nut before machining and the nut on the left is the machined nut ready for assembly
By machining the nut in this way this will allow you to use the standard early headstem seal. you will notice the the later seal is smaller in diameter than the older seal.
http://www.asfphotos.com/upload/1264886476.jpg
Once the nut is machined to suit the inside of the seal (33.9mm) you just assemble the triple clamp set as per normal using all the standard late model parts.
http://www.asfphotos.com/upload/1264882002.jpg
Then it is just a matter of doing something fancy with the steering stops and it is just about done.
this info is relevant for SRAD and newer front ends (unsure about k5 gsxr1000 and newer) going into slingshot gsxr750/1100 and watercooled gsxr750/1100 up to SRAD.