SV650 ZX6R F1 Fork Hybrid

So, after reading all about the potential fork upgrades for the SV, I decided to do something a little different....
A ZX6R F1 hybrid! I chose these forks as they're cartridge forks and I can't find a bad review on handling.
The Idea is that the ZX6R forks have 41mm fork tubes and cartridges that fit, so ideally, I'll be able to drop the cartridge into the SV fork leg and then use the ZX6R fork tube for the top, meaning I can keep the same wheel, speedo drive, brakes and fender but have sports bike suspension for the fraction of the cost of GSXR forks! (Similar to the CBR F3 concept)
I'm not after an extra second off on lap times, just better road handling and less diving!
Now I'm no master mechanic, I've only really done a few minor things on bikes including fork oil change, brake rebuilds etc all with the help from this fantastic forum! So hopefully you lovely lot will be able to help me on this project

Found a pair on ebay in ok nick (not really cosmetically bothered) slight pitting but no leaks amazingly!

I'm hoping to document it all on here for others to use incase they fancy a go themselves, and for help from you guys!
So to start with...

Hoisted up the bike using some ratchet straps and started to get the forks out.



Made sure the brakes where tied up (using the very latest technology in torn plastic bags)



Now here's the first hiccup. Bloody alan bolt holding the front fender stripped (made of brie)



So decided to drill it out from the other side, easy peasy!




After all this some clever sod forgot to loosen the top caps, remember to do this before you start! Only half a turn or you'll cause problems when you lower them off the yolks. I just put them into the lower clamps and did it, made it easier anyway as the wires/cables were in the way at the top yolk.



Ok so just to visualize for later, the ZX6R forks are slightly taller than the SV forks, only by 25-30mm, so if you want to keep a similar geometry, raise the forks by 25-30mm through the top yolk when they go back in.
(SV left, ZX6R right)





Before I started dismantling the forks, I made sure all the setting where set to the standard stated here - http://www.sportrider.com/motorcycle_suspension/
Im not to sure if the compression damping adjuster will cause problems when they slot into the SV fork leg, I can only imagine it'll just have no adjustment, if I'm wrong and it's going to create hell, stop me now!


Now same as with the SV forks, I stuck them in the yolk, and got the top cap loose.


Took them out and started to drain the old fork oil, my god did it stink! Nice and black as well!




Now here comes the second problem that has stopped the project until a solution is found.
I've loosened the alan nut under the ZX6R fork leg to remove the cartridge.



I've definitely loosened them both, but they aren't coming out? and I cant remove the cartridge at all? They both turn with a little force but I can't get them out for the life of me!
Any Ideas?
Any other tips, ideas, comments are welcome!
Tune in next week for more updates!

[jambo]

The bolt at the bottom screws into the internals, not the fork lower, so can just spin. Try pushing the cap back on to use the fork spring to hold the internals still. Alternatively if you can use a rattle gun with a hex socket it should come out.

Jambo

Sent without a real keyboard

[Sid Squid]

The Kawasaki's cartridge a has a square recess in the upper end, I welded a short piece of 20mm square tube to the end of a 25mm tube to make mine, but a suitably long piece of square tube will work, obviously.
Have you checked that the top nut has the same thread?

[mikerj]

Originally Posted by Mikey360

Ok so just to visualize for later, the ZX6R forks are slightly taller than the SV forks, only by 25-30cm, so if you want to keep a similar geometry, raise the forks by 25-30cm through the top yolk when they go back in.

Hopefully you mean mm, or it will look a little odd

Originally Posted by Sid Squid

The Kawasaki's cartridge a has a square recess in the upper end, I welded a short piece of 20mm square tube to the end of a 25mm tube to make mine, but a suitably long piece of square tube will work, obviously.
Have you checked that the top nut has the same thread?

Just looking into making that tool, may get the old man to do it (much better welder than me)
And which top nut do you mean? The upper part of the ZX6R fork and the internals are going into the SV lower forks?

Originally Posted by mikerj

Hopefully you mean mm, or it will look a little odd

You know what, I read that through about 100 times and still missed that!
Will edit now before someone else attempts this and ends up scraping the nose fairing on the road!

Hmmm.... Will be keeping a close eye on this as an idea for myself at a later date!!


Sent from my iPhone

[shiftin_gear98]

Loving your man cave, especially the native wall art.


Watching this with great interest, hope it all goes smoothly.
Good Luck.

[Sid Squid]

Originally Posted by Mikey360

And which top nut do you mean? The upper part of the ZX6R fork and the internals are going into the SV lower forks?

Ah I see, I misunderstood you - how will the compression circuit be affected by use of the SV lower?

[yorkie_chris]

Originally Posted by Sid Squid

Ah I see, I misunderstood you - how will the compression circuit be affected by use of the SV lower?

Been a while since I looked at these but the free bleeds on the piston are absolutely key and I mean the thing you will spend time messing about with to make it work reet. Rest is easy.

Big decisions to make about bleed setup how you set the whole fork system up.

Originally Posted by Sid Squid

Ah I see, I misunderstood you - how will the compression circuit be affected by use of the SV lower?

Originally Posted by yorkie_chris

Been a while since I looked at these but the free bleeds on the piston are absolutely key and I mean the thing you will spend time messing about with to make it work reet. Rest is easy.

Big decisions to make about bleed setup how you set the whole fork system up.

That's going to be the interesting part of this whole project, can't find an SV that's had this done, some SV's over the pond on the rider forum have done it with CBRF3 forks and had great results...... only thing is all the adjustment is done through the top cap on CBR forks so the compression could suffer with these.... Lets wait and see, at the end of the day, it's cost me a tuppence for the forks, so not all will be lost if its a terrible end result!