Front Fork Setups

[sweekster]

I had this front end swap planned for my 600 when i had it. From what i read you can't use anything from the FZR. The forks are bigger (41mm) and the axle is different (bigger). So you have to get the entire YZF front end and it slips right in. No need to press in an FZR stem because they are the same. The current brakes you have will work and there's no speedo gear to worry about-especially since you don't have a speedo gear anyway. 94-96 YZF forks have preload only and 97 on has more adjustments.<- That's the easiest of swaps right there. Honestly Mark, if I were in your position, I'd look for an 03 or newer R1 or R6. Of course this would mean a whole and complete front end with a custom stem but the up side is you'll have full adjustments, the brakes you currently have will work, and your front end will match your rear end alot better.

[PIMPMYFZR]

from what i recall , <reading> the yzf600r are direct swaps just press out the stem from fzr into yzf600r direct fit no welding or other fab needed

[sweekster]

from what i recall , <reading> the yzf600r are direct swaps just press out the stem from fzr into yzf600r direct fit no welding or other fab needed

You don't even have to do that. That's what makes it the easiest of all the swaps. The YZF stem fits in the FZR frame.

[PIMPMYFZR]

o hell no ,
i have a set of top n bottom triples for the yzf600r , my yzf brakes just came in yesterday .. now time to source out the forks and wheel !!!!

[95FZR600]

I hear ya. I would love to have the 03 R6 or R1 but they are a lot of money for me right now. Maybe Ill put this on hold until spring and go that route. My wife will also like this idea.

[95FZR600]

Ok. Im kinda stuck on the 99-02 R6 Forks for some reason. Cant explain that. Maybe cause thats the years of every other MOD I have chosen to date. They are cheaper and you can still find parts if need be. Better upgrade than the FZR and newer. So, being that I still have class and access to a lathe I might try Yamaha George idea he brought up earlier in this thread. If changing the stem to a bolt and just machining it down to fit and you can use the same bearings and pretty much the whole 99-02 R6 setup this way. Sounds too easy and worth a shot.

So, I am going to look for the whole front setup 99-02 R6 and press out the stem. Take the FZR stem and match it up to something I can use on the R6 with threads on both ends and find all the necessary hardware for this swap. I want to find everything for a weekend swap so I wont be out any riding time but then again I can always run the Intruder. Tax time looks like thats when Ill be ready to purchase 99-02 R6 Forks. Little tight on cash right now but I will be doing this swap.

If anyone else is going this route, please keep this thread going with info.

[slayermd]

Ill be doing a 2002 R1 front end swap with a R6 front wheel. Ive checked the bearing numbers and rotor size and it seems that early year R1/R6/FZ's have interswapable wheels. Also, since I will be riding my FZR at the track only, Ive been meaning to PM Modking for his lower triple. That way I have the strongest possible option. But what yamaha_George was saying about the threaded rods is a good idea too but I don't fully understand what is going on with that idea.

When I get all my info Ill post it all up.

[yamaha_george]

But what Yamaha_George was saying about the threaded rods is a good idea too but I don't fully understand what is going on with that idea.

Ok lets see if I can clear this up for you all.

On a standard type bike the upper triple & lower triple are connected by a bolt that is welded an the bottom end and fixed by a nut at the top end applying pressure to true the angle steering bearings.

However a wizard frame maker ( Tony Foale{google is your pal here} got fed up with trying to mate steering stems from one make of bike to other frames ie his own racer models for pro racers. .

What he did was trim off the original stem just above the lower bearing, then shove a big say 1/2 or 12mm bolt or in most cases just 12mm threaded rod up thro the truncated lower bearing centre,up thro the steering head on the frame, thro the center of the top bearing and using large washers & suitably used double nuts fasten the whole lot together as you would with a hollow stem but this time using the long threaded studding.

Now providing you torque up the steering bearings as per normal the whole shooting match works.

No fancy machining just a hack saw & remember to cut the threaded studding with the nuts on it so you can use them to thread clean the ends

I will see if I can scare up a triple clamp and show in picture how it works for New Years if possible.

[slayermd]

But what Yamaha_George was saying about the threaded rods is a good idea too but I don't fully understand what is going on with that idea.

Ok lets see if I can clear this up for you all.

On a standard type bike the upper triple & lower triple are connected by a bolt that is welded an the bottom end and fixed by a nut at the top end applying pressure to true the angle steering bearings.

However a wizard frame maker ( Tony Foale{google is your pal here} got fed up with trying to mate steering stems from one make of bike to other frames ie his own racer models for pro racers. .

What he did was trim off the original stem just above the lower bearing, then shove a big say 1/2 or 12mm bolt or in most cases just 12mm threaded rod up thro the truncated lower bearing centre,up thro the steering head on the frame, thro the center of the top bearing and using large washers & suitably used double nuts fasten the whole lot together as you would with a hollow stem but this time using the long threaded studding.

Now providing you torque up the steering bearings as per normal the whole shooting match works.

No fancy machining just a hack saw & remember to cut the threaded studding with the nuts on it so you can use them to thread clean the ends

I will see if I can scare up a triple clamp and show in picture how it works for New Years if possible.

Great explanation! I don't know why I didn't get it the first time. Well, I can be guinea pig on this one. I think it's worth a shot and really easy to do. If anything goes wrong all I really waste is a stem. When I get my stuff in, I can do a write up for the it.

[95FZR600]

Very well said George!

Rob (cad600) and I were talking about it tonight and its pretty straight forward. This way, you can use any front end you would like. Your new setup(whole) can be used this way. Not piecing things together from fzr, yzf, gsxr, r1, r6...etc....Pick a setup and use it all.

One question for yamaha george,

I thought the stems were pressed in? Therefore, using a threaded rod on both ends of lower and upper?

[95FZR600]

[slayermd]

I think your supposed to cut the stem just above the bearings.

[95FZR600]

I guess you can cut it but I have a 20 ton press to pop it out with.

[yamaha_george]

Very well said George!

Rob (cad600) and I were talking about it tonight and its pretty straight forward. This way, you can use any front end you would like. Your new setup(whole) can be used this way. Not piecing things together from fzr, yzf, gsxr, r1, r6...etc....Pick a setup and use it all.

One question for yamaha george,

I thought the stems were pressed in? Therefore, using a threaded rod on both ends of lower and upper?

95,
It is just one length of threaded rod so you put a big washer and double nut each end, but me being paranoid I weld the lower nut in place on the rod.
Leaving a stub of old stem in place on the lower clamp makes it easier to center the bearing, like wise you could make a bush at the top end as well but Tony to my knowledge did not use either.

[yamaha_george]

I guess you can cut it but I have a 20 ton press to pop it out with.

With a 20 ton you have no problem I used 10 ton on crankshaft building etc. the trick is the tooling being strong enough (or at least stronger than the items push fit