K3 650 with a gsxr 1000k2 front end

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The bike got Smashed up 2 months ago so I thought I'd go for the gsxr frontend I wanted but didn't take the plunge. I've gone for

k2 tho forks with 750 k3 top yoke
Hayabusa tokico 6 pot calipers
My sv galfer lines
Tl1000 clip ons
Srad 750 front wheel with discs
Honeywell sensor from rs

As this set up does not bolt straight on if had alot of running around and Agro but the end result has been worth it as I have a matching front wheel to the rear and nice big brakes :)

http://i97.photobucket.com/albums/l204/shiver85/5a3a5775.jpg
http://i97.photobucket.com/albums/l204/shiver85/d5b21bc2.jpg

I managed to get panels I needed and sort out the spares I had. As this was being done on a budget I gave spraying the panels myself a Toyota e53 red. While I was at it I gave the engine a coat of vht metallic grey
http://i97.photobucket.com/albums/l204/shiver85/b0785703.jpg
http://i97.photobucket.com/albums/l204/shiver85/ba62379c.jpg

Started getting the front end to work by turning down the front spindle and making a spacer to bring the wheel centre to the forks. Once that was done mdf templates were made to mount the calipers and house the speedo sensor. These were then sent to the Cnc guy to make the final product

http://i7.photobucket.com/albums/y254/cabbie1/DSCF0001-43.jpg

http://i7.photobucket.com/albums/y254/cabbie1/DSCF0002-24.jpg

http://i7.photobucket.com/albums/y254/cabbie1/DSCF0003-31.jpg

http://i7.photobucket.com/albums/y254/cabbie1/DSCF0001-44.jpg

http://i7.photobucket.com/albums/y254/cabbie1/DSCF0002-25.jpg

http://i7.photobucket.com/albums/y254/cabbie1/Blade900/003.jpg

Wheel powder coated and new bearings/seals

http://i7.photobucket.com/albums/y254/cabbie1/001-1.jpg

Bearings/seals in and disc's fitted

http://i7.photobucket.com/albums/y254/cabbie1/002-1.jpg

Caliper hangers

http://i7.photobucket.com/albums/y254/cabbie1/001-2.jpg

Had to remove 2mm from the caliper mounts to get them dead centre to the disc's

http://i7.photobucket.com/albums/y254/cabbie1/002-2.jpg

All centred.

http://i7.photobucket.com/albums/y254/cabbie1/004-2.jpg

Speedo pickup fitted

http://i7.photobucket.com/albums/y254/cabbie1/005-2.jpg

All done and ready to fit to bike.

http://i7.photobucket.com/albums/y254/cabbie1/006-1.jpg

[speedplay]

Love the MDF templates :)

[maviczap]

Lovely work there

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Front end dropped in lovely
http://i97.photobucket.com/albums/l204/shiver85/ffb944f5.jpg

More fitting and slowly putting back together didn't realise how much I took off

http://i97.photobucket.com/albums/l204/shiver85/bb0b6dff.jpg
http://i97.photobucket.com/albums/l204/shiver85/5d70eab8.jpg

I enlarged the hole in the frame for the lock stop as it was only afew mill out
http://i97.photobucket.com/albums/l204/shiver85/07b3a121.jpg

I found nothing seems to line up or clear as the bottom yoke was catching on the fairing, all the headlight loom, hid loom and heated grips makes it a right mess and in yet to trim it back and give some better clearance.

I need to drill and tap the bottom yoke as it has no stops and the steering is just odd without them.

http://i97.photobucket.com/albums/l204/shiver85/ec71f0ae.jpg
http://i97.photobucket.com/albums/l204/shiver85/fcf7a5b0.jpg

It's all built and ready to go other than making everything clear and fine tune the speedo sensor as it's over reading with 4 magnets on a 9 spoke disc anyone have any ideas?

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Can anyone help with the over reading of the speedo?

[speedplay]

Try Yorkie_Chris.

Hes buggered about with most Gsxr front ends in the past.

[yorkie_chris]

Try increase spacing of sensor. It may be picking up on disc bolts or rivets as well as magnets.

Lovely work, can't fault it... except for being very puzzled about why you would get probably £100s worth of CNC work done rather than just buy some GSXR1000K2 calipers?!

[svdemon]

Speedo healer will sort it

[yorkie_chris]

Speedo healer will but it is just a band aid... couple of washers are easier to try first of all!

[widget]

Ah ha that makes sense I have got it set very close will have a go on Monday when I'm back at work

[yorkie_chris]

What's going on with the right hand side fork leg? They did not normally have a shiny section there IIRC

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Not too sure it came like it from eBay so I'll get the bottoms repainted when I strip the bike down again for the respray

[beabert]

Nice work, huge brakes.

Id love to have access to all the fancy metal work machinery, id make my own bike lol.

[fastdruid]

Lovely work, can't fault it... except for being very puzzled about why you would get probably £100s worth of CNC work done rather than just buy some GSXR1000K2 calipers?!

Even then I'd personally avoid the 6 pots (unless the GSXR1000's are better than the TL/busa/GSXR750's)

The 6 pots are *ace* when 'fresh' with new pads but they suffer badly with worn pads and wear badly which increases lever travel.

http://farm5.static.flickr.com/4086/5191709347_00e728d320.jpg (http://www.flickr.com/photos/fastdruid/5191709347/)
Caliper wear (http://www.flickr.com/photos/fastdruid/5191709347/)

I got fed up of mine in the end, especially dealing with things like this regularly.
http://farm5.static.flickr.com/4085/5192295980_1aa731cb51.jpg (http://www.flickr.com/photos/fastdruid/5192295980/)
6 pot caliper rebuild - again (http://www.flickr.com/photos/fastdruid/5192295980/)

Druid

[fastdruid]

What's going on with the right hand side fork leg? They did not normally have a shiny section there IIRC

At a guess its been down the road, scraped the fork bottom and cleaned up by taking a few mm off.

Druid

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The reason I had those calipers fitted is because I picked up the wheel discs mudgaurd and calipers for less than the cost of the calipers alone so decided to do things differently to what others have done.

The bike will not be trashed or raced so having the brakes spot on isnt needed

[fastdruid]

I mostly had mine on the road, to be fair those calipers had done ~37k of which ~36k was on the road.

I still wouldn't choose 6 pots again, they need a yearly rebuild and its a right pita to do all 12.

Druid

[yorkie_chris]

The bike will not be trashed or raced so having the brakes spot on isnt needed

I disagree completely with this.

Brakes binding, overheating and locking on will possibly kill you no matter how much of a faggot you're riding like.

There's no excuse for not having spot on brakes.

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Well their only spongy at the moment I'll keep on them till their right

[fastdruid]

Well their only spongy at the moment I'll keep on them till their right

I never managed to get mine right for more than 5 minutes. Massive amounts of power but never had the feel that other setups have[1].

Druid

[1] Best so far has been CBR600RRR3/4 calipers with fireblade M/C on an NC35.

[Bibio]

well done. a lot of hard effort and noggin scratching has gone into that conversion. but i have noticed one thing that may be of concern, the front brake lines look too tight.

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That's what I noticed but what will I notice if they are too tight?

[yorkie_chris]

When you open the throttle or go over a dip the line will get wrenched out of the fitting and you immediately loose all brakes :)

They could be too tight or they could be OK... just make sure that full extension of the forks is not pulling them tight.

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Nice. Well I'll get it up in the air tomorrow and see how much slack there is. If none I'll get a set made up

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The lines have enough slack but just tidy it up im getting a longer set made up.

The brakes were tested and got 150 on the rear 190 on the front which ain't bad from a bike that weights 120 on the front and 135 with rider on the rear :)

Mot passed just afew little bits to sort like higher clip ons as the tl ones are too low then she's finished

[leebex]

Looks very very nice, and do like seeing things fabricated. :cool:

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So had afew bits highlighted to me after the mot and got to work making some lock stops as the last owner had ground them right down and i didn't like the idea of my rad being the new one.

Once again front end off and forks out which sucked as I had only finished the build but needs must and it ment I could check everything again.

I centre punched the remaining the stops then drilled from 3mm up to 6.5mm then fitted a nut and bolt to each one. I will fit bigger lots when I get some but these will
Do for the mean time.

http://i97.photobucket.com/albums/l204/shiver85/5f9f5644.jpg

Heated grips are coming back off until I find a set of clip ons with a higher rise as the tl
Ones just seem too low for my liking and first give me enough clearance with everything
In place.

More to come maybe next week when I've got more money

[fastdruid]

FWIW What I did originally was fit a (IIRC) M8 cap screw bolt with a number of washers on it and a lock nut to keep it tight into the yoke. If I was to do the same again I'd do similar but turn up a nicer spacer rather than the washers.

However I bought a set of lockstops off the a guy in the states, they're made of nylon and fit over the radiator mounting points and the fork legs hit against them.

Druid

[yorkie_chris]

I don't think that would work on pointy, I don't think they have a rad bolt on far side (unless you whip that off and tap a hole)

[fastdruid]

Ah, I presumed them to be the same. Carry on... :-)

Druid

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Theres a nut below the head of the bolt which lines up nicely with the frame so might have some made up and get then welded in place or just leave it with the bolt but keep an eye on it.

Yc you were right about the sensor being too close I spaced it out and is working a treat just like the old sensor :)

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So following on this happened
http://i97.photobucket.com/albums/l204/shiver85/92cdb97c.jpg
So I did this
http://i97.photobucket.com/albums/l204/shiver85/fc454008.jpg
And fitted these
http://i97.photobucket.com/albums/l204/shiver85/723a22bc.jpg
http://i97.photobucket.com/albums/l204/shiver85/0b8087a1.jpg

[mikerj]

What happened to the tank?

One thing that confused me - it looks like the speedo sensor is aligned to pick up the slots in the (aluminium?) disc carrier. Is this right?

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I had the sensor mounted there as I attached the magnets on the carrier

[Skip]

I am no expert but did you use TL1000R clip-ons instead of TL1000S - might explain why they are a bit low..?

Great looking bike though 8)

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I havnt got a clue to be honest either way they clear enough or I'm just use to them

[monkey]

What did happen to the tank?

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Not sure the only fix is respray

[454697819]

please excuse the dumb question, but is your front tyre fitted with the wrong rotation?

Rest of the work is lovely btw, shame about the tank.

[widget]

If your making reference to the pilot 3 tyres no thats the way the thread is cut

Cheers the tank attack was a right kick in the nuts but the bike was due a respray anyway