TwinFrontRotors
just thought i would do a write up, for future modders the first step in the process is getting the donor fornt end, i would get a complete front end (wheel, yokes, brakes, mudguard,etc) as opposed to what i did and got bits and pieces from every where, it ended up that i got the wrong calipers, the second set were to wide so needed some grinding. up to you really.
1. get new forks and yokes,
2. I pressed out the stem from the donor forks (GSX 750 in my case) but nearly every Suzuki has a very similar width stem.
3. get your gs stem(or if like me you can't afford to have the bike off the road, buy a bottom yoke off eBay)
4. press out the gs stem from its yoke,
5. i found that the gs stem was about 1/16th of a mm smaller than the GSX stem so i got an engineer/turner to knurl the bottom part of the gs stem to "swell" it, which worked a treat,
6. press the gs stem in to your donor yoke
7. fit new bearing,. (available from busters, Wemoto, and probably your local bike shop as well) you'll need a piece of pipe just wider than the stem but not too wide, don't want to damage that shiny new bearing :D
8. pop your bike on the center stand, and start pulling your old gs front end apart, remove clocks, headlight handle bars and any thing else that is attached to you original forks (brakes) now, un bolt the center nut on the top yoke, unbolt the 2 bolts on the top yoke that clamp the forks, the whole front end should slide out in one unit now,
9. get your pre-prepared front end with bottom yoke loosely attached, and with your headlight bracket, clip on handle bars(if used) in place, and slide it in the same way you slid out the old one.
10. put in new top race bearing
11. put you new top yoke (you will have to remove the old ignition switch, i used a grinder to get it off the old yoke, and used 2 6mm screws and screwed it to the new one) on and put in the center bolt to hold everything in place.
12. tighten every thing in place, before you put your headlight back in check your steering stops.. i had to grind about 10mm from each side of the stop on the frame to get a decent steering circle.
(this pic is from Lev and Sean's rgv install)i also had to grind away the steering lock thing(the top metal thing)
13, now its just a matter of reinstalling your headlight, coming up with a way to install clocks, putting all the electrics , throttle, mirrors etc back into place,
14. next on the cards is brakes, its time to bleed those bad boys, and get them nice and stiff, its basically just like bleeding you single caliper brake, but you have to do it to both sides to make sure there is no air in the system, its an arduous process,
and that's it basically
OK things to remember
1. headlight bracket and indicators to fit(remember if you have the naked version that is) that your headlight bracket wont fit your new forks along with your indicators
2. get new bearings (called head race bearings, the come in a set of 2, one for the top, and a larger for the bottom)
3. make sure you have all the brake lines a new master cylinder to handle all the extra fluid that it will be pumping. also new pads are a good idea as well, may as well do it now while its easy.
4. lots of brake fluid, get a 1 litre from Halford for £7 you wont use half of that but its always handy to have around the house :D
5. having another set of hands, although not essential is always appreciated, i got mine for cheap, a few beers and a couch to sleep on(code name Essex-Joe)
6. having beer on hand is nearly essential, and i think that's it.