Fork Off!
2005 GSX-R 600 fork and caliper swap onto 2006 SV1000s
Installing an upside down fork and radial calipers on a 2006 SV1000s is something many owners are interested in doing. Having just completed this swap myself, I can say with complete assurance that the actual work is quite simple, providing you start with the correct parts and tools.
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I have read a lot of different processes for swapping a late-model GSX-R fork onto a SV1000, but most of those seem to contain misleading or inaccurate information. When I decided to do this swap for myself, I decided to write a clear (albeit a bit long) process, with a clear parts list, based on my recent ‘05 GSX-R 600 fork and caliper swap. I apologize for the length, but I hope it will serve others looking to do this same swap.
Materials:
Starting with a fork and brakes from a 2004-2005 GSXR 600 seemed to me to be the easiest route, because many SV parts could be re-used.
Here is the complete list of parts I used for the swap. If it isn’t listed, you don’t need to buy it. The reasoning behind each part is included where needed.
- 2005GSXR 600 fork
- 2005GSXR 600 radial calipers
- 2005GSXR 600 upper and lower triples
- Speed Research carbon fender fender
A stock GSXR 600 fender would, of course, work as well but the SV fender won’t work with the new fork. - Custom machined spacers to fit the GSXR calipers to the SV rotors
The calipers were designed to work with 300mm rotors. The brakes on the SV 1000 are 310mm.Dimensions:
Outer diameter: 24mm
Inner diameter: 10mm
Thickness: 5mm
Cost: 60 dollars for 4 at local machine shop. I am sure I could have got these cheaper, but I wanted them done the next day, and 60 bucks is cheap compared to a new front wheel and rotors. - LSL “offset match” 50mm clip-ons with a 1.5 inch rise, and LSL bar ends
The stock clip-ons will not fit around the larger fork tubes, and stock GSXR clip-ons do not preserve the comfortable riding position of the SV, and leave very little room (read: not enough) between the stock fairing and the grips. - Race Tech springs
I weigh 175 lbs with no gear, and the SV weighs at least 40 pounds more than the GSXR 600. The added weight of the bike alone necessitates a stiffer spring to get the intended performance out of the fork. The stock GSXR 600 springs are around .85s). I factored the extra weight of my bike in to the Race Tech spring rate calculator (i.e., 175+40 = 215 lbs “rider weight”) to figure the correct rate. Plus, the stock spring rate on the SV is .98 anyhow, and it was sprung pretty well for me, just not damped well enough. - Redline synthetic fork oil
Lightweight/Medium cocktail mixed 65/35 to achieve about 6.5w - A new left grip
I bought a new one so I could cut the old one off rather than wrestling with it and fighting grip glue. - Some small strips of rubber
From a bicycle tire inner tube, for example (see process below).
Time:
- Budget one weekend day. I spent about 6 hours, including cleaning and bleeding the brakes, re-springing and oiling the fork, etc.
Difficulty (one bleeding knuckle to five bleeding knuckles):
- Two bleeding knuckles for just the swap, three bleeding knuckles if you re-spring the fork. This ain’t rocket science.
Process:
- Re-spring and oil the GSXR fork.
You will need a fork spring compression tool, such as this one sold by Traxxion Dynamics. The tool comes with excellent instructions. Follow them, and take your time. I added 6.5 weight oil to a height of 115mm. This is the hardest part of the job. When you are done, take a break and have a beverage. - Raise the bike with a front stand, and support.
I used jack stands on cinder blocks to support the innermost part of the frame sliders. - Remove the fairing.
- Remove the ignition assembly (held on with loctited 40mm security torx bolts).
I bought a security torx bit for a ratchet at an auto parts store. - Remove old forks, clamps, and clip-ons.
- Remove the controls from the old clip-ons, and tie/hang them aside with stiff wire or zip ties
- Remove the brake lines from the SV calipers, and get brake fluid everywhere.
- Clean up the brake fluid mess.
- Remove, clean and grease the old bearings, then re-use them.
The Stock GSXR 600 bearings can be used if you prefer, they are the same. - Install the GSXR fork, triples, and new clip-ons.
I ran the tops of the fork caps flush with the top triple, for maximum length. - Install the ignition assembly into the new triple clamp.
Note that it fits perfectly, and the steering lock works just fine. - Install the controls, grips, and end caps onto the clip-ons.
The starter and turn signal assemblies have plastic locator pins which seat in a matching hold drilled into the clip-ons. Rather than jigging and drilling the clip-ons, I dremel-ed off the locator pins, and used a very thin strip of rubber between the assemblies and the bars to prevent them spinning when installed. Works fine.
I bent and re-used the brake fluid reservoir bracket by mounting it to the LSL clip-on bolt. - Install the GXSR Fender onto the fork.
- Install the SV wheel with SV axle.
- Attach the brake lines to the new calipers.
- Attach the calipers to the forks, with the spacer mentioned above.
- Remove the bike form the supports using the front stand.
- Bleed the brakes.
- Replace the fairing.
- Take a picture and have a beer.
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That’s a lot of steps, and many are simplified, but aside from re-springing and oiling the fork, there is really nothing tricky about it.
May 24th, 2007 06:16
hello, this manuel isn’t to long is just fine,
i bought a week a go a complete 600k5 front end so this manuel is very handy for me.
jeroen
June 15th, 2007 06:26
Thanks for the great write up. I am doing my 600K5 front end on my 05 SV650…. One question though.
Will your spacer method for re-using the SV wheel work on an SV650 also??? I would like to re-use my existing wheel instead of buying more parts. Please let me know!
Thanks in advance!
Marcel
June 15th, 2007 09:48
Marcel,
I don’t think this will work with an SV650 wheel, as the SV front rotors are 290MM – which is 10MM smaller than the stock GSXR rotors.
The spacer was required because the SV1000 rotors are 310 MM, which is larger then te GSXR rotors, so the caliper needs to be moved further from the akle to fit.
I think you will need to score a GSXR wheel and rotors for your SV650 swap. Maybe you can do just the rotors, I am not sure.
Chris
September 5th, 2007 03:25
Hi I’m replacing my front end with a k7.
A few more mods needed as the lock is on the wrong side.
but a k5 top yoke with the stem drilled out works fine.
I was just wondering what make are your crash protectours?
Good write up, helped me out a lot
cheers.
December 12th, 2007 20:19
I have an ‘04 SV650 and have a set of forks from an ‘06 GSXR 600 on the way including wheel and brakes with lower triple clamp. It looks like I will have a black front wheel and a silver rear…yuk!
My problem is in finding an ‘06 600 upper triple clamp. The ‘05 upper triples are much more available. What is the size of the new stem hole to make an 05 upper triple work with ‘06 forks? The fork lock working would be a definite plus.
Thanks for the write-up!
Lew
December 20th, 2007 17:06
How did you get the bike up on the jack stands/cinder blocks? Skyhook?? or did the usual front fork stand lift the bike high enough to put the stands under the frame sliders?
PS I am going with the LSL standard bar conversion for the ‘06 GSXR 600 upper triple…way pricy!
December 20th, 2007 18:45
Lew –
I don’t know much about the 06 forks – or the sv650 swap in general… btu I do know that your LSL upper clamp conversion will solve your issue nicely!
A skyhook would have been nice, but I used a standard set of front and rear stands to lift the bike. I put 2×4s on the ground under the wheels of the stands (on each side of the front and rear tires), so that when I “jacked” the bike up on the stands, the stands woudl be on the 2×4s, and thus be 1.5 inches higher up thwn if I used just the stands on the ground.
Those LSL bars will be super cool! Good luck with your project and feel free to post a link to some completed pics in a comment here when you are done – I’d love to see the bars.
March 6th, 2008 22:29
Nice post, been a huge help! I have a 07 sv650s. I picked up a pair of 2k7 gsxr forks with calipers, and read the post about the sv650’s havin a 290mm roto. So my question is will gsxr 750 rotors fit on the sv 650 rim??
Any info will help thanxx!
Dave D
March 19th, 2008 09:08
I found this blog from a link someone had posted on SV rider.com
I see you had already bought your spacers, but I also make spacers and do not charge that much. So, if any of your friends do the same or similar swaps, fell free to contact me for spacers.
Thanks, DougZ
March 19th, 2008 09:11
sorry, left out website:
http://www.dougzcustoms.com
March 24th, 2008 13:21
Dave – Sorry, I am not sure if the rotor will work. Good luck with the swap!
DougZ – Thanks for letting people know about the spacer machining. Cool SV products on your site as well!
June 7th, 2008 09:57
Hi ,you have done perfect work.I have a gsr 600 (k6)and i want to put the same fork with radial brakes.I cant find the right the up fork plate.Can you help me?
I want a plate with holes for my steering wheel(Ihave not clip-on)Thank you….
July 17th, 2008 02:42
Great write up!
August 8th, 2008 22:23
Excellent write-up, thank you!
August 29th, 2008 12:06
exactly what does changing the front fork from stock to inverted do, pros, and cons. i have an 06 sv1000s and i haven’t thought about it but was wandering what the fuss is all about
Thanks
August 2nd, 2009 15:08
Hi
Great post. I was originally intending to perform this conversion using an SV650 but now think it would be better to go with the thou’ (Don’t need to source a wheel for instance). One other issue I was looking into with the 650 was the speedo ‘drive’ as this comes off the front wheel, you don’t mention this in your write-up, is this because the thou’ speedo does not come off the front wheel?
(I am not too familiar with the thou’)
Regards
Brendan
August 20th, 2009 23:34
GREAT write up.
Killer illustrations.
Now you just have to add fork sliders install for those who might have an interest.
November 15th, 2009 13:48
nice page !!!! worked out well for me.I was wondering about the sterring damper your showing in the pics.I would like to do the same.Do you remember the name of the website and or what kind it is ???? >>>>>thanks in advance
January 25th, 2010 20:25
You interested in selling the calipers that you took off of the bike?
January 29th, 2010 19:43
Already sold, but thanks for the interest!
May 6th, 2010 12:23
I’m also curious to find out if GSXR 300mm rotors will fit on an SV650 front rim.
Can someone please provide this info or a link to where I may find it, other than the numerous already searched forums
Thanks