K6 GSXR Fork Retrofit Complete

[kuhlka]

Nah, I've still got the 509 wheel and need to sell it as I don't have rotors for it. I might just stick with what I've got then with my stock axle. It'd just be nice to have the thicker axle as its easier to use and doesn't stick out like my 03.

[DEcosse]

On 2006-11-11 18:26, kuhlka wrote:
Nah, I've still got the 509 wheel and need to sell it as I don't have rotors for it...

Aaah, yes - had forgotten about the rotor mounts being different (6 bolt on earlier model vs 5 on later)
I'd also like to check on a potential other difference for reference of others:
Did you ever check the rotor spacing on your setup?
On my year wheel (as mentioned in opening post) it required spacer shims to align the rotors perfectly in the centres of the K6 GSXR calipers (01 bike a friend is converting also required the same but that is same generation essentially).
Centre to centre between the rotors/calipers is 132mm on the GSXR - was 129 originally on my 97-01 wheel between rotors before adding the shims between the wheel hub & each rotor. They did 'fit' between the calipers but were very offset towards the inside piston on each side - now are dead centre with the shims.

[kuhlka]

Mine aren't centered perfectly and are similar to what you describe. I can measure things later to give a more exact number, though if necessary.

[DEcosse]

The shims are as simple as M10 washers which were pretty much ~ 1.5mm thick - just use 6 (or 5 in your case) between the rotor & the wheel hub on each side - that should do the trick.
I may ultimately get some full circle spacers made up for when I eventually get my waves but this is working fine for now.

This is how it ends up - note in second pic that it appears like a bigger spacer than actually is, the rotor already has an offset away from the wheel hub which makes it look more.

p.s. My forks aren't really that ratty - just dust on there that the flash decorates incredibly!





[ This message was edited by: DEcosse on 2006-11-12 10:59 ]

[DEcosse]

Some new pics of the finished article:











[ This message was edited by: DEcosse on 2006-11-28 16:00 ]

[Martin_R]

On 2006-11-10 19:38, DEcosse wrote:
Here is the complete spacer & steering stop-lock kit.
It's amazing how some of the simpler things are so rewarding - I am particularly proud of the caliper spacers.
The original GSXR caliper mount utilizes a male locator bush that is pressed into the fork mounting post: I removed these & as you can see made the caliper spacers of a double-ended design to facilitate the process.

Is the bushing on GSX-R only for locating or for taking the braking load?

So if the GSX-R Tokicos were to go on the stock 1050 fork bottoms, they will be fine without the bushing and with the bolts taking the whole load?

I don't remember if the S3 fork bottoms had a bushing or male locator of any kind. I'll have to drop by the garage later today & check.

[DEcosse]

On 2006-11-20 02:12, Martin_R wrote:

Is the bushing on GSX-R only for locating or for taking the braking load?

You mean the caliper spacer one, right?
It is required on the retrofit using the OEM size Triumph rotors (or equivelant size after-market) because the Triumph uses 320mm rotors, while the K6 Suzuki has 310mm (K3/4 has 300mm).
The spacer is 5mm making up the difference in radius (155 to 160).

So if the GSX-R Tokicos were to go on the stock 1050 fork bottoms, they will be fine without the bushing and with the bolts taking the whole load?

My understanding is that the fork mounting on the late model Triumphs accounts for the correct radius without any requirement for a spacer. I have not validated this personally but many have made the retrofit of the Tokicos to the 05/06 S3 without one.

[Martin_R]

On 2006-11-20 10:24, DEcosse wrote:
You mean the caliper spacer one, right?

Yes.

My understanding is that the fork mounting on the late model Triumphs accounts for the correct radius without any requirement for a spacer. I have not validated this personally but many have made the retrofit of the Tokicos to the 05/06 S3 without one.

You are correct. I was just interested as to why the Suzuki people have used the bushing in the fork lower in the first place. Why did they not make their fork lowers to fit the rotors they are using?

I guess they would not have gone through all the trouble just to have a male locator, but the bushing is there also to take some of the braking load from the bolts? Yes? Or just as a spacer?

[Martin_R]

.

[ This message was edited by: Martin_R on 2006-11-20 12:16 ]

[DEcosse]

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 ]