West Coast,RSA summer project

[giantkiller]

I have a bunch of pictures in my images on the forum here.
But for some reason I can't bring them over to the threads anymore. So I downloaded this from my images to My phone. So I could bring it here
If you blow up the picture you can see I had made some pins to keep the bars from rotating. When raised for touring. But decided not to use them. Just tighten the clamps down and never had a problem. Even when the Deer killed itself on my chest. Didn't move.

[aj52]

Bike is finally totally stripped down.
I am going for the GXSR fork mod as the FJ's forks are badly pitted.
I wanted to put RPM valves in,but because of the pitting aswell,it will increase the cost for repearing to much.

The mod is going to be a cheaper option.
If done some research on the Suzuki between the K5/6 and K 7/8 on Gixxer site. Struggle to get parts for K7/8.

Everything has the same numbers,except:
Bottom Fork diameter:K5/6 is 54 mm,K7/8 is 56
Triple clamp offset is:K5/6 is 30,K7/8 is 28
Oil height is:K5/6 is 101 while K7/8 is 124.
Then on top yoke,the ignition switch is in centre as FJ's,while K7/8 is off centre to the left.

Hannes

[aj52]

Hope it uploads

[Pat Conlon]

Dan has done his homework on this mod. 

The GSX-R1000 2007/2008 model years were chosen as donors for a reason.
They have (as oem) the heavier .976kg/mm fork springs which works well with the heavy FJ's.
One less thing to worry about. (Buying New fork springs and rebound/compression valves)
The other year GSXR's used lighter fork springs....fine for a 400lb sport bike, not so good for our's...
http://www.racetech.com/ProductSearch/2/Suzuki/GSX-R1000/2007-08

Dan and Fred will chime in....

Remember, to think about....what to do with your speedometer.

[aviationfred]

I copied this from a post on my fork mod thread that Dan posted.

[/ Just  little on why I went with the 2007-2008 gsxr 1000 front end. I found out that alot of the racers were actually going to lighter springs, that the forks were oversprung from the factory. So I thought they would be good for the heavier FJ. I actually had to soften the preload up when on the FJ. So while I'm no suspension expert.( Actually, I have my racer buddy set them up for my weight. And then fine tune them until I find what I like) But I think they are as good as your going to get. Without changing the springs/valving. After I finished the first one. I thought it handled great... But what did I know. So I had my racer neighbor (was 3rd in points locally for 3 years on his gsxr 1000, anyways not just your average track day racer) take it for a ride. To see if it was any good. Or if I had just made a mess... He wasn't real fired up about it. But agreed to take it for a spin.... He was gone so long I thought he must have crashed. When he finally came driving back up the driveway. I could see a huge grin through the faceshield of his helmet. He got off. And the first thing he said was "I don't know what you did to the geometry. But you got it just right!" He said " I was expecting a big heavy wallowing bike. But this actually turns in better than my Gixxer." He went on to say that he took it on the road he uses to check suspension settings for his race bikes. Corners with stutter bumps. And couldn't get it unsettled. So I know I've stumbled onto something good. (Rear suspension was Honda f4i shock/with 900lb eibach spring and he's 100lb lighter than me) Disclaimer. But the bike/bikes are way better than I can ever push them. Kookaloocolor]

[aviationfred]

Here is a parts list that I made of what is needed to do the GSX-R1000 front end mod. These parts will give you a 100% identical front end as the 3 FJ's that Dan (giantkiller) and the 1 FJ that I have done.


Here is the itemized list of the parts required for this mod. I have done my best to identify all models and years that the parts can be sourced from. If the parts states only 2007/2008 GSX-R1000, than I highly recommend only using the part from that model and years.


Front wheel          2005-2008 GSX-R1000, 2006/2007 GSX-R750, 2006/2007 GSX-R600

Forks                   2007/2008 GSX-R1000

Rotors                  2007/2008 GSX-R1000

Calipers                2005-2008 GSX-R1000, 2006/2007 GSX-R750, 2006/2007 GSX-R600

Fender                  2007/2008 GSX-R1000, 2008/2009 GSX-R750, 2008/2009 GSX-R600

Top Yoke               2007/2008 GSX-R1000
upper triple clamp

Steering stem        2007/2008 GSX-R1000
lower triple clamp

FJ Steering Stem    1984-1990 interchange, 1991-1993 interchange only with said years.

FJ Steering Stem    all years, Items 3-7 in the parts breakdown diagram
Hardware

Handle Bars           Tarozzi clip ons, 50mm diameter, 70mm rise

Brake line              Spiegler Stainless steel braided, Single line 820mm length with 20 degree banjo fittings. The length and fittings may vary due to the type of master cylinder used.

Suzuki crossover    2005-2008 GSX-R1000, 2006/2007 GSX-R750, 2006/2007 GSX-R600
brake line

Bar ends                HVMP heavy weight (14oz.) each. pressure lock style

Fender bolts           6 total, the 4 forward bolts are one part number and the aft 2 bolts are a another part number. The parts diagram only says 2 required for the forward mount. Order 4. These can be found
                            in titanium

Caliper bolts           4 total, these can be found in titanium

Rotor bolts             10 total, I used titanium, slightly less weight, reducing rotating mass

Fork Extensions      Custom fabricated to Dan McCoy's (giantkiller) specs. Purchased as finished items from Dan.

Top Yoke Bushing    Locally fabricated.

I left out hand grips, brake pads as the type and brand used is a personal choice.

Over all this mod is fairly straight forward. For skills required, If you can change your own fork seals, than this mod is in reach of your skills. Very minor machine work is required. I don't have the equipment to do this and I outsourced the work. The steering stems are pressed out of the lower triples. The FJ stem requires the lower end to be very slightly enlarged by adding some weld. Then turned down and press fit into the Suzuki lower. The top yoke bushing is simply to take up space between the two upper threaded areas and the hole in the Suzuki yoke.

I hope this helps anyone else that is interested in doing this.


Fred

[aj52]

Hi Pat & Fred

According to that chart,the spring rates are the same,just the lenght that differs.
The chart is a bit dull. I got it at www.gixxer.com/forums.

Thanks Fred for the list

[aviationfred]

I myself am beginning this same mod again. I have begun ordering the parts I need. I will proceed with the install after the first of the year, once the weather gets cold.

Here is the front wheel in my living room, waiting to be installed.

Something that I did not have listed is a 90 degree valve stem. The rotors are 310mm Dia. leaving the straight valve stems installed makes checking tire pressure a pain in the rear and getting an air chuck positioned to add air even more frustrating.


Fred

[aj52]

Hi Fred

I've read about the FJ that you had done this mod on,has been stolen.
Good to see that you at it again to do another one.

Dan,
Can you please give me the dimensions on the fork extenders that you have manufactured for Fred and yourself.


Thanks
Hannes

[aj52]

Hi everyone

I went for the R1 front end as I couldn't get K7/8 parts here in RSA.
Know I probably need to get stiffer fork springs,but will adress that later.
Bottom triple in for the steering stem to be machined.
Going to use FJ's top triple,has the same offset as the R1.
The fork extender s will be fabricated according to that. By doing this,I can use original clamps. And steering lock will still be functional.

Hannes

[giantkiller]

Hi everyone

I went for the R1 front end as I couldn't get K7/8 parts here in RSA.
Know I probably need to get stiffer fork springs,but will adress that later.
Bottom triple in for the steering stem to be machined.
Going to use FJ's top triple,has the same offset as the R1.
The fork extender s will be fabricated according to that. By doing this,I can use original clamps. And steering lock will still be functional.

Hannes

Sorry Hannes I don't have a set on hand and have Long since lost the plans I had drawn up. I just order a set from the machinist. He has saved the program for the CNC machine. He has a spare set right now but I'm sure shipping would be prohibitive.

[Pat Conlon]

Hey Dan...Shipping may be expensive to South Africa but, it is what it is, you have the only sets of these extenders available in the world.

[FJmonkey]

Sorry Hannes I don't have a set on hand and have Long since lost the plans I had drawn up. I just order a set from the machinist. He has saved the program for the CNC machine. He has a spare set right now but I'm sure shipping would be prohibitive.

Dan, I can reverse engineer that set if they are not needed right away.

[aviationfred]

Sorry Hannes I don't have a set on hand and have Long since lost the plans I had drawn up. I just order a set from the machinist. He has saved the program for the CNC machine. He has a spare set right now but I'm sure shipping would be prohibitive.

Dan, I can reverse engineer that set if they are not needed right away.

Mark,

I actually have set of Dan's extensions that are not yet in use.


Fred

[giantkiller]

Thanks Fred I didn't want to say anything for you. The only thing I have access to are the extensions I had welded on and machined down.