Has anyone ever tried to bore our front triples out to 41mm? I want to fit a new front end without all the work of getting a new wheel and a new gauge setup.

I haven't measured the stock clamps, but I honestly think it would be easier just to use some from an SV650 or something. A spacer or two will let you use the stock front wheel and mounting the gauges should be easy too.

got a complete gsx750 front end.... weld/bolt 2 tabs on for the guages......
swap stems ore use spacers..... i think i have one already converted......
central NC

I feel like if you just bore them out, then you're going to need a smaller spacer to slide onto the front axle, and would have to shave the speedo as well ||-()-|| vs | |()| | <--Does that make sense to anyone?

you will weaken the stock tripples.....
if installing  kat forks everything .... SHOULD   line up   but the strength of the tripples will be very questionable

You think 4 MM is anything significant as far as that goes?

Remember its 4MM diameter so thats only 2mm of material taken off the triples

I'm in agreement with werase643 here. It seems like a better idea to swap out the front end, as opposed to taking material off of OEM equipment that was already built down to a price.

Quote from: crzydood17 on December 29, 2012, 06:57:15 PM
You think 4 MM is anything significant as far as that goes?

Remember its 4MM diameter so thats only 2mm of material taken off the triples

Yes.

If you attempted to bore out material - you'd need the proper milling equipment. It must be perfectly circular, perfectly vertical and the upper and lower triples must match EXACTLY.
I would challenge the most experienced machinists to do it correctly.

Don't attempt it.

Swap the front with the correct triples.

It wouldnt be at all difficult for someone with the gear and the knowhow. Industrial machine shops carry out jobs like this constantly.

A lathe or a vertical borer would do it. Hold it in a 4 jaw chuck or fix it to a faceplate and make a few passes with a boring bore. The hardest part would be clocking it up to the original bore and getting it to run true, tricky but not impossible.

Something like this....

If cost/time wasnt an issue a fixture jig like this could be knocked up making it easier to hold and clock. 



I wouldnt want to do it though because I believe it would seriously compromise the strength of the clamps, particularly in an accident situation. 2mm doesnt sound much to remove but how much is it as a percentage,

Strangely I agree here its not impossible to do in a machine shop nearly anything is possible. Why not just get clamps to suit and press the GS stem in and away you go.

i never measured but i don't really remember there being too much material there to begin with. i'd measure those wall thicknesses first.

whats the purpose for wanting a new front end?  Performance or Bling?  If its performance your after, without doing a front end swap to a newer bike, just get new internals.  Plenty of A pace guys running stock front ends with upgraded internals with no issues. 

Bling?:  well gotta pay to play.

Id pass on boring out the triples too.  I am doing a swap on my track bike to a 08 600rr front end.  No stem swaps, just spacers and new tapered head bearings. 

Quote from: RichDesmond on January 01, 2013, 11:16:00 AM

Quote from: crzydood17 on December 29, 2012, 06:57:15 PM
You think 4 MM is anything significant as far as that goes?

Remember its 4MM diameter so thats only 2mm of material taken off the triples

Yes.

i would listen to this fella.

Quote from: catch2otwo on January 03, 2013, 08:19:06 AM
whats the purpose for wanting a new front end?  Performance or Bling?  If its performance your after, without doing a front end swap to a newer bike, just get new internals.  Plenty of A pace guys running stock front ends with upgraded internals with no issues. 

Bling?:  well gotta pay to play.

Id pass on boring out the triples too.  I am doing a swap on my track bike to a 08 600rr front end.  No stem swaps, just spacers and new tapered head bearings.

I'd say this is what he wants a performance upgrade I've recently had my eyes opened to the importance of suspension adjustment on a bike and the sheer level of maintenance that we simply are not aware of. But I'm waffling, if you can upgrade the whole front end really just about anything is better than the stock GS front end.

Id say if your going to go through the trouble time and money on boring your triples and possibly have them fail in the name of getting better forks you really might as well do a front end swap.  Your really not doing much more work. In both situaions the whole front end comes off the bike.  With the front swap you snd yor triples to bob and he sends them back ready to install.  Assemble, fabricate a bracket for your gauges and headlight and your done.  Chances of parts failing or working against each other are much slimmer.   

But i feel like if OP cant be bothered to invest in the effort of a swap, the next best thing is putting better internals.  That is sufficient for 90% of riders

Yet the next decision upgrade your internals or swap? which one will give you the most adjustability for the lowest outlay? For me personally if I had my gs I would swap front end to one that is fully adjustable that I can later on upgrade those internals. And would definitely have the r6 shock.

Honestly I just want dual front brakes without having to go through the HELL of figuring out how to get all the guages right.

Sv650 or the front end that burning1 has should be the go unless there is another cheap easy one. Honestly IMO I would stay brand loyal in the front if it was me

Quote from: slipperymongoose on January 03, 2013, 08:42:32 PM
Yet the next decision upgrade your internals or swap? which one will give you the most adjustability for the lowest outlay? For me personally if I had my gs I would swap front end to one that is fully adjustable that I can later on upgrade those internals. And would definitely have the r6 shock.

My reasoning for upgrading internals was based on opinion.  I do not know OP's riding skill, unless hes running fast B and A group paces, upgrading the internals would seem to be the most cost effective and easiest and SAFEEST option seeing how he doesnt want to invest effort into a true swap. 

Im with you 100%, I'd rather swap front ends with something which I have.  I have done the R6 rear shock as well.  Mine is a track bike so more adjustability the better. 

good luck op.