So an ongoing nonstarter project of mine is restoring a crashed '01 GS. It needs a new frame and fork. I have a lead on a frame, but no lead on a fork (not even on this board). However, I just got an idea. My other bike is a FZR600, and I have some FZR600 parts lying about, and FZR forks are going on eBay for happy cheap. Thing is, FZRs have a 38mm fork. Is it possible/safe to "re-bore" the triples to 38mm and jam one or two of these forks in? If this works, I could have a nice FZR front end with dual rotor, and rockin clip-ons, all of which would make me happy. (Yeah, I'd replace the wheel, calipers, & MC as well.) Otherwise, I could still do the same, but I have to mess with making the bearings work/fit and that's more effort. I have to check the length of the fork, but I believe the FZR fork is longer (to acommodate the clipons) and I could push through the top triple to maintain the correct geometry.
Any other unforseen problems that I haven't forseen? I don't really have time to undertake this project, but that probably won't stop me... As long as the result is rideable.
Since the GS didn't use tapered rollers you can probably make it work pretty easily with the propper bearings. I'll have to hunt up part numbers and dimensions but bearings should be pretty easy to find.
Oh, I should have asked if there are any different bikes I might consider ripping forks from. EX500 parts are plentiful, and the fork diameter is the same, but it's not really a step up from the GS forks (single rotor, etc). Plus I think Yamazuki sounds slightly better than Kawazuki. Other bikes I'm just not familiar with, and people don't list fork tube diameter in eBay listings... But I like the idea of fitting a bearing that makes it work. Far more professional-like.
Okay, mak. Inspired by your post, I found this site:
http://www.crc2onlinecatalog.com/steering_head_bearings.htm
Notably, the GS500 and FZR600 have the same part number. Can I conclude that the steering heads should be compatible? If so, this could be an easier project than I thought.
I would stick the common Katana/GSXR conversions...I prefer running with TL1000R forks (S forks are longer) and inverted 750 and 1000 setups.
And no...the FZR600R uses tapered bearings on top and bottom, the GS does not. I can't find the inner diameter of the FZR bearings, though.
there are some gs forks on ebay.
http://cgi.ebay.com/ebaymotors/2004-Suzuki-GS-500-FH-Front-End-Forks-Triple-Tree-04_W0QQitemZ260040912175QQihZ016QQcategoryZ35592QQrdZ1QQcmdZViewItem
yeah a gs front end is EXACTLY what he's looking for.
...pay attention...
hey mak...have you ever actually seen a GS....or worked on one?
talk about pay attention......
GS's have tapered steering stem brgs
http://houseofmotorcycles.bikebandit.com/partsbandit/oem_schematic_view~schem_dept_id~715592~section_dept_id~1~section_dept_name~OEM+%28Stock%29+Parts~dept_type_id~2~model_dept_year~1998~model_dept_mfr~Suzuki~model_dept_id~703282~model_dept_name~GS500EW.asp
I also happen to have a 94 KAT 750 complete front end with brakes/rotors....missing fender and wheel (GS will work)
also got a lead on another '05 salvage title'd frame
haven't seen it
should see it next week
worked on several...and they've all had the same, un tapered bearings that are listed on Suzuki's, BikeBandit's, and RonAyer's microfiches. Maybe they're different affter 2003...I wouldn't know then.
I'll also mention that when I mounted up a K4 GSXR 1000 front end to a 1995 model bike, I used untapered bearings on both ends. The built TL1000R setup that went on the 2003 used the same bearings (they were untapered). Both bikes used the stock GS lower bearing.
You guys are all really angry people.
Anyway, thanks for the link to the GS front end. If it goes for $9.99, that's certainly the easiest way to go! The site I linked to lists tapered roller bearings for the GS. That implies to me that either that's what they come with or the roller bearings can be used as a replacement. I don't know, because bearings are not my thing.
No look at what's pictured in that link. The bearings are tapered, but they fit in a bevel thingy whopper that flushes all the sides so they'll fit in an untapered enclosure. This is because tapered bearings are self-centering with wear, and there's more contact surface, which limits wear. The majoraty of the aftermarket replacements you'll find are untapered or are sealed into fittings similar to those in the link.
chuck,
Mak and I don't always see eye to eye....many times we do
the FZR 600 forks are fine if that is what you have
of the 10-12 GS's that I have torn apart or rebuilt...all have had tapered roller brgs
i've never worked on a 01-up... all old turdy ones
the big switch back to roller ball brgs....on modern sport bikes.....LIGHTER WEIGHT
the nice thing about yam and suz they use the same ID brgs for the steering stem on many bikes
25mm top / 30mm lower
check the length between the bearing surfaces on thegs and the fzr
should be close....
the FZR forks are small by todays standards...but they are better than the GS forks
also 99-02ish R-6/1 calipers mount straight up...for the super bling look....also better race pad selection
Quote from: werase643 on October 12, 2006, 07:09:53 PM
of the 10-12 GS's that I have torn apart or rebuilt...all have had tapered roller brgs
I'll bet ya a dollar you can pop out a little insert from the bearing well that looks a lot like the ones in the link he posted. I'm hoping to be tearing one apart soon...I'll snap some pics. O0 :thumb:
REgardless, though, if you wanna mount up the FZR front then you need to get a measurement of the stem's bearing surface. I can't find it with part numbers because it's only listed as a tapered assembly. With that number we can find you some bearings that fit.
Ditto the R6 stuff...if you go this route get some R6 calipers and an R1 master. I had an FZR front end on my old FZ600 and that particular brake setup was the shaZam!.
im sure you could just slide in the fzr forks into the gs triples(yokes what ever you want to call them)
you might have to use the gs wheel and get some discs from a bandit 4 or a rgv or some thing like that be cause the gs has a large single disc, the calipers on the fzr won't fit. youll need smaller ones. i don't think you could use the fzr wheel if you used the gs triple clamps. because i think(im not entirely sure on this) the fzr uses a 3.5inch rim and the gs rim is only 3"
but the long and short of it, i personally think you can get it to work.
good luck what ever you decide to do, and don't let these angry guys get you down :D
Quote from: hmmmnz on October 13, 2006, 03:20:01 AM
im sure you could just slide in the fzr forks into the gs triples(yokes what ever you want to call them)
you might have to use the gs wheel and get some discs from a bandit 4 or a rgv or some thing like that be cause the gs has a large single disc, the calipers on the fzr won't fit.
I'd probably use the FZR wheel, rotors, and calipers, and master cylinder in that case. That way I can be sure, once the compatibilty of the triples or head bearing is sorted out, there will be no other issues.
I definitely like the R6/R1 caliper idea. It seems that's what everyone in the FZR forum is doing, too. (The nice thing about the FZR is the similarly roubust online community. I'd have plenty of people to help me with my Yamazuki.)
What I think I'll do is try to pick up BOTH the GS fork and FZR fork. If the deal falls through on either one, then that will make my decision. Otherwise, I'll go the FZR route first and try for my hot blingy hybrid. If that fails I'll go for the boring dependable plan with the GS front end. Whatever I don't use I'll re-sell.
Quote from: Chuck on October 13, 2006, 07:49:22 AM
Quote from: hmmmnz on October 13, 2006, 03:20:01 AM
im sure you could just slide in the fzr forks into the gs triples(yokes what ever you want to call them)
you might have to use the gs wheel and get some discs from a bandit 4 or a rgv or some thing like that be cause the gs has a large single disc, the calipers on the fzr won't fit.
I'd probably use the FZR wheel, rotors, and calipers, and master cylinder in that case. That way I can be sure, once the compatibilty of the triples or head bearing is sorted out, there will be no other issues.
I definitely like the R6/R1 caliper idea. It seems that's what everyone in the FZR forum is doing, too. (The nice thing about the FZR is the similarly roubust online community. I'd have plenty of people to help me with my Yamazuki.)
What I think I'll do is try to pick up BOTH the GS fork and FZR fork. If the deal falls through on either one, then that will make my decision. Otherwise, I'll go the FZR route first and try for my hot blingy hybrid. If that fails I'll go for the boring dependable plan with the GS front end. Whatever I don't use I'll re-sell.
as i said before, i think the fzr wheels are wider.(and on the fzr the forks are spaced wider apart to accomidate the extra width)
so you will probably have to use the gs wheel ( if infact the fzr wheel is wider)
you may be able to use the discs though , im not entirly sure. i think its going to be... have a play and try and sort it :D
i think you can do it though
good luck
Right I gotcha. I'd only be able to use the FZR wheel if I use the FZR triple.
yeah i think so. have a look at the fzr wheel and see if its a 3" or a 3.5"
or better yet measure the distance between the forks on the fzr.
It's a 3".
The first year FZR600, in '89, had a 3.5" rear rim; in '90 they went to the FZR400's 4" rim. The front has remained a 3" for all the years.
sweet then chances are every thing will slide into the gs yokes with out too much trouble. you should be able to use the fzr wheel discs and every thing. bonus:D
if any thing is amiss you may have to use the gs speedo dive and spacer from the other side other than that should be easy sailing:D
the gs forks are 37mm so using the 38mm fzr you should be able to loosen the yokes, and tap them on with a mallet with out real issues :D
Actually that's not a good idea...your yokes aren't the most sturdy things and doing that will screw up the bolt alignment. It's not safe. When you take into consideration that any machine shop will bore the yokes out to 38mm for next to nothing, it's simply not a good trade.
or do what he says.. i still reckon its worth a go first if its too tight then take them to a shop and get the mm ground out :D
good luck either way
the only forks that will slide into the GS tripples.... 87-91 HURRICANE 600
wheel /brakes/ everything.....
only bad thing....2.75 x 17 rim
but with slight mods... a F-2 3.5 x 17 will fit
Quote from: werase643 on October 13, 2006, 05:31:27 PM
the only forks that will slide into the GS tripples.... 87-91 HURRICANE 600
wheel /brakes/ everything.....
only bad thing....2.75 x 17 rim
but with slight mods... a F-2 3.5 x 17 will fit
thats not true.
a gpx 750 has 37mm forks as well, but uses a 3.5 inch wheel
Quote from: werase643 on October 12, 2006, 05:28:57 PM
also got a lead on another '05 salvage title'd frame
haven't seen it
should see it next week
Ken, you already know what I want off of that frame O0
Quote from: hmmmnz on October 13, 2006, 05:50:08 PM
thats not true.
a gpx 750 has 37mm forks as well, but uses a 3.5 inch wheel
He wasn't meaning just the forks....he meant the whole front end. The GPX assembly may have 37mm forks, like about 9000 other models, but the spacing is too wide.
yep but what he said and what he meant are 2 different things.
:D
im not a mind reader :D
I found a '04 GS500 fork for cheap, which might just be the end of this saga... That will save me from having to buy a bunch of the FZR parts. However, I'm still shopping so if I can find these parts for a good price I'll still give it a shot. :)
I measured the steering head on the FZR and it's one inch longer than the GS's. So if I still go for it, I'm thinking putting the FZR fork in at least the lower triple would be the easiest way to go. While I was measuring I forgot to measure the distance between the tubes, so I gotta remember to do that when I'm home...
If you end up not wanting the '04 fork, let me know what "for cheap" is, I may be interested. I'm supposed to be getting some freebies, but I dunno how long I can wait for em...
No secret. It was $150 for the tubes and triples in mint condition. If I end up not using them I'll pass them along at cost plus shipping.
Cool, thanks. Hopefully I won't need em. I'm expecting some free ones...
NGFL....I got kat 750 forks/tripples/h-bars/caliper/master cylinder/ and pair of rotors.....200 +
everything except a GS wheel and fender!!!!!!!
or 200 if you come get them....i'd rather not box them
If someone can tell me where to get a complete fork/lower triple for the 500F I would really really appreciate that.
Let me edit that to Please Lord God someone help me. I figured I would switch the whole fork/lower triple thing out this winter to fix the problem with my bike rather than sell it.
Look on ebay right now there is a whole fork setup for an 04 on there. Also, if you guys are trying to match up bearing and what not. Why don't you just find bearing slightly smaller than what you need and have a machine shop make spacers out of something like 410 stainless steel, press fit it into the steering stemm of the frame and then press fit the smaller bearing into the spacer. It is a simple project on a lathe. You just have to find bearing that would work and make the spacer to match. That might be harder than it sounds for someone who is not a machinist though. I wish some of you were closer I would make some parts.
Why cant I find it on ebay? Anyone have a link?
I might have a lower triple & bearings available soon. I just bought a complete fork assembly but I just needed the tubes. If the parts are undamaged and I decide not to bore it to 38mm to try my FZR fork idea, I'll make them available here.
Hey, I appreciate that. Please let me know when you decide. I rode today but the whole front end problem on my bike still has me shaking my head every time I'm on it.