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I'm not sure if I'm confusing you, or you're confusing me, Martin!
There is no 'spacer' per se on the OEM GSXR to set the correct radius - there is only an internal bushing (which you normally can't see at all) that is pressed into the fork fitting that positively locates a corresponding female opening in the caliper.
The additional 5mm is only required when using GSXR fork plus GSXR caliper combo (which was designed for a GSXR 310mm rotor) on a Triumph 320mm rotor.
Without a spacer on the Triumph rotor caliper would be too far inboard. But obviously on the OEM GSXR it aligns perfectly.
Similarly, using older 03/04 forks and calipers which were intended to utilize that year's 300mm rotors, would need a 10mm spacer to make up the 320mm diameter of the Triumph. Again, there is no spacer used on that year GSXR either, but the caliper mounts are correspondingly shorter (or conversely, the 05/06 calipers have a 5mm longer mount built in to accommodate the change from 300 to 310mm rotors)
Presumably if the 05/06 Tokicos fit the 05/06 Triumph 320mm without a spacer, then the additional radius delta between the Triumph & GSXR rotors is accommodated by the fork mount itself on each respective bike. It would be useful if someone could just post up the relative dimesnions of the two respective calipers between the Tokico & Nissins.
Note however if 03/04 GSXR Tokicos were used on 05/06 Triumph, then a spacer would indeed have to be utilized as their mounts are indeed 5mm shorter.
When I designed my spacer part, I combined the functions of the OEM locator bush with a spacer to have one single part to do accommodate both requirements for Triumph wheel/rotor on GSXR fork/brakes
Interestingly, I should mention that I found that the top caliper mount (on caliper itself) is very slight clearance fit over the bushing (not interference press fit like the way the OEM bushing fits in the leg), while the lower one (only) is similar as top one in the horizontal plane, but actually has noticeably more clearance in the vertical plane. This was same for both calipers so is intentional.
i.e. lower caliper mount holes are elongated vertically while the top ones are perfectly round.
I imagine this allows the caliper to 'grow' in the vertical plane as it gets hot.
Did I just help to further confuse the situation? :-D
[ This message was edited by: DEcosse on 2006-11-20 17:57 ]
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