Z650 into 810 project

[Pigford]

What diameter are the ZX9R forks - I've got some ZZR1100 which I'm fitting to the Harris, and they're 43mm.

[Crofty]

I will check tomorrow piggy, but fairly certain they are 43mm too. Crofty

Edit, they are 46mm

[Crofty]

Pigford the forks I have are 46mm

I have got my lower yoke back and trial fitted the front forks in. I made up some dummy shims to replicate the size of the taper roller bearings. Just a bit smaller outer diameter and bigger internal diameter so I can slip them on and off the stem and out of the frame.
I have a front and rear wheel coming that will allow me to fit 160 rear and 120 front rubber, then I will fit some tyres to make a rolling chassis and calculate what rear shock length is needed.


Forks being trialled


Side view.

Wheels turned up a short while ago, so hung them on,


New side view with wheels hung on.


Front wheel and big discs.


Rear end with wheel to fit 160 rear tyre.

[Pigford]

I've got a pair of rare MICRON alloy caliper adaptors for ZZR forks, that may well fir yours if you find a need - they're to fit all the Suzuki Nissin & Tokico 4 & 6 pot calipers

[Crofty]

I will let you know Mark, I do have a very good machinist in York now, he just did my yokes very quickly for me and his stuff is great. Those wheels are Zephyr 1100 btw.

[j.b]

i like those wheels mate....are they 17"?
dunna listen to piggy trying to sell you his tat tho , the 4/6 pot tokico calipers will bolt straight onto those forks if you have 300mm diameter discs....all you need is to alter the offset to suit

[Crofty]

jb, The wheel sizes are 18" front and 17" rear, will be able to fit 160 rear and 120 front.
Was trying to stay away from having to have 17" at both ends when I had already lost a bit of height at the front, I have room to machine a bit away under bottom of top yoke and I could always tailor it a bit with length of rear shock, a bit will depend where chain run is.
Then there is the option to make fork top extensions.

[Pigford]

i like those wheels mate....are they 17"?
dunna listen to piggy trying to sell you his tat tho , the 4/6 pot tokico calipers will bolt straight onto those forks if you have 300mm diameter discs....all you need is to alter the offset to suit

The hole spacing for ZZR forks is 63mm with 320mm discs - the Suzook are 90mm spacing I think, or summat like that

[Royalratch]

jb, The wheel sizes are 18" front and 17" rear, will be able to fit 160 rear and 120 front.
Was trying to stay away from having to have 17" at both ends when I had already lost a bit of height at the front, I have room to machine a bit away under bottom of top yoke and I could always tailor it a bit with length of rear shock, a bit will depend where chain run is.
Then there is the option to make fork top extensions.

Smart. I'm still at least an off from standard rake / trail even with dropped yokes but I could have easily spec'd an 18" front wheel.

[Crofty]

Baldylocks, which Zephyr swingarm did you use?, The 550/750 look alike, but the 750 has beefier bracing, presuming the 1100 is different again.
The 550 I bought slots straight in to the point of just sliding in snug and will need no spacers etc, its slightly longer and shock mounts look to be spot on for width.
The wheel I have is from a Zephyr 1100, its 4.5 wide fits OK into the 550 swingarm and will take 160, you mentioned using a ZXR750 wheel with 180 tyre and machining under sprocket to get chain aligned, I won't be going that big on tyre, but wondered if machining required or just offset front sprocket? Anyone know or is it try it and see? Crofty

[paul doran]

i like those wheels mate....are they 17"?
dunna listen to piggy trying to sell you his tat tho , the 4/6 pot tokico calipers will bolt straight onto those forks if you have 300mm diameter discs....all you need is to alter the offset to suit

Piglet on the make again

[Baldylocks]

Crofty, I used a 750 Zeph Swingarm so not sure about the 550 altho they do not appear to be dis-similar, also I used a stock 750 axle and had spacers made up to fit for the zxr wheel so I didn't have to change bearings, you probably will not have to machine the sprocket carrier ..but u will need an offset drive sprocket, with the 810 motor I originally had a 13 mm offset sprocket made which you are welcome to try for the cost of postage, that was with my machined down Rear sprocket carrier, which left little clearance to the tyre but as you are using a 160 should give a good 10mm clearance.

cheers

Martyn

[Crofty]

Cheers Martyn, I have a slightly off set sprocket to try that j.b gave me, it will do for a start. Jim

[Crofty]

The zephyr swingarm shaft that it pivots on inside is larger, machine shop is making bushes to sleeve it down to std Z650 through bolt size.
Just waiting on some axles turning up to see what I need to do for the wheels.

[Royalratch]

I also had sleeves made to get the ID to suit the frame bosses. Also means you can run nice modern bearings too.