Ok, the forks are on, still have some minor details like the headlight, front fender and brake pads to install, but, I figured I would post up what I have done to get to this point.
krushnuts R6r Forks, the thread that started it all:http://www.600riders.com/forum/fz6-mods/18846-r6r-forks-doable.html
Also check out 4drfocus's R6r Fork Swap:http://www.600riders.com/forum/fz6-mods/32360-r6r-front-end-swap-finished-finaly.html
and Scottn's R6r Fork Swap:http://www.600riders.com/forum/fz6-mods/32681-2009-r6-front-end-project-complete.html
Parts:
- 1998-2001 R1 Forks: I used 2001 R1 forks, $180 on ebay (1998-2001 are the same, 2002 on use a different axle and 2003 on have a different center post diameter at the bottom than the FZ6)
- Used FZ6 Lower Triple $50 (So I could experiment without destroying my triple)
- 1998-2003 R1 Brake Calipers: I got 2002 brake calipers, $90 ebay, because they had the gold anodized caps instead of the blue from previous years.
- Optional 1998-2001 R1 front wheel spacers, $5 ebay, I found out during the install that the FZ6 spacers worked fine, but since I had them and the dust seal covered the whole bearing area I used them.
- 2, M8 - 1.25 X 25 mm Hex head bolts to mount your ignition, $1.35 at Lowes.
- 1, 3/4" Crimp Ring: Pack of 10 at Lowes for $3. You will need to insert this in the R1 Top Clamp around the top of the FZ6 Center Post as the Diameter at the top of the Center Post is 22 mm and the inside Diameter of the R1 Top Clamp is 27 mm, this still leaves about a 1 mm gap all the way around when installed.
- Handlebar risers: I used these from Motorcycle, ATV/UTV and Snowmobile Parts and Accessories - Dennis Kirk, Inc, $66
I had to drill and tap a hole between the two existing mounts to bolt it to the top clamp, I screwed the original bolts into the original mounting holes and cut them off about a 1/4" long, I then drilled 4 holes in the top clamp for these to fit in to keep the risers stable.
Ok, I think that is everything, so what we are essentially doing is swapping out the R1 Center Post for the FZ6 Center Post. In order to do this you will need to remove the retaining ring from both triple trees located at the bottom underneath the lower triple tree around the bottom of the center post (see picture below) Once you have done this you will need a hydraulic press to press out the center post and then press them back in.
To remove the retaining ring you will need to dremel off the lip around the edge of the lower triple that is right over the ring. Once you have dremeled the lip off, you can pry up one end of the ring and remove it with a pair of needle nose. You will reinstall the ring by getting one end started in the groove around the bottom of the center post and then working it into the groove by tapping it in all the way around, once it is seated in the groove the center post is unmovable.
Once you have the center post swapped, simply take off the front tire, brakes and forks.
Install your R1 Forks using all of the FZ6 bearings, bolts and pieces, be sure to regrease your bearings at this point.
The most difficult part, getting the ignition off of the FZ6 Top Clamp. I attempted to drill out the bolts, no dice, so instead I used a hacksaw to cut below the ignition where the top clamp mounts to it (wasn't going to use the top clamp again anyhow
) once I cut through the bolts the ignition came right off.
Now, since the R1 top clamp sits closer to the frame and the FZ6 has that ugly bunch of metal poking out right below the top clamp, the ignition is not going to fit. So, I cut and grinded the back of my ignition down until it cleared and mounted, you will notice that there is a steel pin in the area you need to cut and grind, this is the pin that allows you to lock the steering on your bike, if you do it right your steering lock will still work, thankfully mine does.
Mount your wheel and brakes (you will need to place one washer between each of the brake mounting points so that the calipers line up with the rotors) and enjoy.
krushnuts R6r Forks, the thread that started it all:http://www.600riders.com/forum/fz6-mods/18846-r6r-forks-doable.html
Also check out 4drfocus's R6r Fork Swap:http://www.600riders.com/forum/fz6-mods/32360-r6r-front-end-swap-finished-finaly.html
and Scottn's R6r Fork Swap:http://www.600riders.com/forum/fz6-mods/32681-2009-r6-front-end-project-complete.html
Parts:
- 1998-2001 R1 Forks: I used 2001 R1 forks, $180 on ebay (1998-2001 are the same, 2002 on use a different axle and 2003 on have a different center post diameter at the bottom than the FZ6)
- Used FZ6 Lower Triple $50 (So I could experiment without destroying my triple)
- 1998-2003 R1 Brake Calipers: I got 2002 brake calipers, $90 ebay, because they had the gold anodized caps instead of the blue from previous years.
- Optional 1998-2001 R1 front wheel spacers, $5 ebay, I found out during the install that the FZ6 spacers worked fine, but since I had them and the dust seal covered the whole bearing area I used them.
- 2, M8 - 1.25 X 25 mm Hex head bolts to mount your ignition, $1.35 at Lowes.
- 1, 3/4" Crimp Ring: Pack of 10 at Lowes for $3. You will need to insert this in the R1 Top Clamp around the top of the FZ6 Center Post as the Diameter at the top of the Center Post is 22 mm and the inside Diameter of the R1 Top Clamp is 27 mm, this still leaves about a 1 mm gap all the way around when installed.
- Handlebar risers: I used these from Motorcycle, ATV/UTV and Snowmobile Parts and Accessories - Dennis Kirk, Inc, $66
I had to drill and tap a hole between the two existing mounts to bolt it to the top clamp, I screwed the original bolts into the original mounting holes and cut them off about a 1/4" long, I then drilled 4 holes in the top clamp for these to fit in to keep the risers stable.
Ok, I think that is everything, so what we are essentially doing is swapping out the R1 Center Post for the FZ6 Center Post. In order to do this you will need to remove the retaining ring from both triple trees located at the bottom underneath the lower triple tree around the bottom of the center post (see picture below) Once you have done this you will need a hydraulic press to press out the center post and then press them back in.
To remove the retaining ring you will need to dremel off the lip around the edge of the lower triple that is right over the ring. Once you have dremeled the lip off, you can pry up one end of the ring and remove it with a pair of needle nose. You will reinstall the ring by getting one end started in the groove around the bottom of the center post and then working it into the groove by tapping it in all the way around, once it is seated in the groove the center post is unmovable.
Once you have the center post swapped, simply take off the front tire, brakes and forks.
Install your R1 Forks using all of the FZ6 bearings, bolts and pieces, be sure to regrease your bearings at this point.
The most difficult part, getting the ignition off of the FZ6 Top Clamp. I attempted to drill out the bolts, no dice, so instead I used a hacksaw to cut below the ignition where the top clamp mounts to it (wasn't going to use the top clamp again anyhow
) once I cut through the bolts the ignition came right off.Now, since the R1 top clamp sits closer to the frame and the FZ6 has that ugly bunch of metal poking out right below the top clamp, the ignition is not going to fit. So, I cut and grinded the back of my ignition down until it cleared and mounted, you will notice that there is a steel pin in the area you need to cut and grind, this is the pin that allows you to lock the steering on your bike, if you do it right your steering lock will still work, thankfully mine does.
Mount your wheel and brakes (you will need to place one washer between each of the brake mounting points so that the calipers line up with the rotors) and enjoy.
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