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simplyj 10-30-2015 06:21 PM

TBS winter project checklist and questions
Hey guys,

planning my winter modding session on the TBS and think I'm getting close to a plan. I've combed through quite a few of the posts but, although I have a finished product in mine, I haven't been able to come up with a definitive list of "other parts" needed such as gaskets and the like. This is particularly pertinent to the cam swap as well as any mag wheel swap tips.

As for the plan, it involved an USD front end, mag wheels, green can swap, and some necessary maintenance. Below is my admittedly crappy photoshop rendering of what I'm planning:

Suspension & Wheels:


k6 GSXR 600 forks. Specs: 738mm stock length + 15mm extenders = 752mm overall length (29.6"). 310mm rotor size. All balls racing fork swap bearings ordered. I lucked out finding a set of used forks that have GP suspension internals & extenders and that were set up for a 175lb (in gear) rider, which is just about my weight.

05+ zx6r front wheel with zx14 310mm rotors. I am unsure of the width of the hub so hopefully will work with the gsxr forks. Gsxr wheels are out as I hate 3 spoke wheels with a passion and would prefer not to relive the 90s.


zx6r shock (no real need for it but I have one sitting around and it's more compact than the TBS remote reservoir shock).

05+ zx6r rear wheel with zx11 250mm rotor and 530 sprocket. Trophy rear brake assembly (caliper, bracket, torque arm). The rotor diameter is 5mm less than the Trophy, but that's less than 1/10 an inch of reduced pad contact, so I'm not too worried.

I don't know for sure that any of the above will work, but I think it's worth a shot and hey, that's half the fun of custom stuff. I really want to switch to mags as this is my daily rider here in NYC and sits out on the street all riding season. Mags are lighter, easier to maintain, fit standard size sportbike tires, and infinitely easier to clean. If I can't get the zx6r wheels to fit, I'll throw em back on ebay and pick up an 08+ Harley narrow glide dual disc hub and hayabusa rotors or the cognito moto front hub and stick with spokes.


Green cams & rejet

igniter off 98hp Triple or programmable unit

check/adjust valves

change fluids & flush cooling system

for this, I assume I need a head gasket as well as 25mm shims. I'm going to get a Haynes manual prior to going down this road, but could certainly use some real world pointers as well as a parts shopping list for gaskets, shims, etc.


White paint



WSC 10-30-2015 08:17 PM

No need for a head gasket. (The head doesn't come off to change the cams.)

The valve cover gasket is reusable.

An assortment of shims is helpful, but if you're not rushed you can just order the ones you need.

Zee9 10-30-2015 09:33 PM

TBS winter project checklist and questions

I have a Haynes manual if you wanna borrow it (for the job)

IrlMike 10-31-2015 05:35 AM

Looks like a plan stan! :)

The cam swap won't mean any shim changes, by itself. They'll only be needed if clearances are already out of spec. (All the base diameters remain the same, and Triumph's maching is done to far higher tolerances.)

It's not worth buying any new shims until you know what you need. You'll probably find some will swap into other positions, so out of say 5 that need adjustment, only two new shims will be needed.

If you're going to use the GSXR yokes with a much smaller offset than stock, unless you tilt the bike forward to steepen the effective steering head angle, the steering response will be markedly slower.

In rough terms, you'll need to tilt the ride heights about a *total* of 70 to 80mm. By total, I mean the sum of increased ride height at the back and decreased ride height at the front. For easy trigonometry calculation, you may assume the total tilt to represent the short vertical side of a very long and skinny right angle triangle, where the wheelbase is the 'adjacent' side to the small angle. Strictly speaking, the wheelbase will also shorten by a couple of inches (a good thing for agility), but this doesn't change the accuracy of calc much. (You might want to alter the photoshop job to get an idea what it will look like.)

In other words, to keep a reasonably agile front trail figure, the GSXR yokes (or any modern sport bike - they all use similar geometry) will also need the much steeper steering head angle these bikes use as well.

simplyj 10-31-2015 12:06 PM

I meant valve cover gasket, just mistyped. 😀

IrlMike, thankfully this isn't my first usd fork conversion and plan to raise the rear a bit to compensate. Also given the slight decrease in rear tire diameter, I'm lucky to have a good amount of fork real estate to experiment with moving them up or down in the triples. However, it being a decade since I last owned a sportbike, I've found the TBS front wheel to be a little twitchy and am actually looking to reduce that a bit.

Zee, I'll certainly take you up on the offer for the Haynes.

Lower gsxr triple and zx6r front axle arrived yesterday and the forks are arriving today. As winter is approaching and my garage space fell through, I've also had to order a 6x8 temporary garage for the backyard to do all this work and store both bikes. Should be a fun winter

IrlMike 10-31-2015 04:06 PM

Ouch, that's a small space to be doing all this.. but great stuff - looking forward to your pictorial updates! ;)

simplyj 11-01-2015 02:05 PM


Originally Posted by IrlMike (Post 7079089)
Ouch, that's a small space to be doing all this.. but great stuff - looking forward to your pictorial updates! ;)

Yeah, but living here in NYC I'm used to living and working in cramped spaces.

joechin 11-01-2015 09:52 PM

Great looking project. Definitely keep us updated. I would like to do an USD fork conversion in the future myself.

joechin 11-02-2015 04:58 PM

Which exhaust do you have in your photoshop picture? Looks like 3to1, that already installed?

Zee9 11-02-2015 06:12 PM


Originally Posted by joechin (Post 7086417)
Which exhaust do you have in your photoshop picture? Looks like 3to1, that already installed?

Jason - I totally missed the 3-1 exhaust. If you are planning that too, then count me in for sure. I'm dying to do that too

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