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.

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

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
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.