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Project: Suspension Upgrade

59224 Views 199 Replies 28 Participants Last post by  Pyke13
11
ZX10R suspension upgrade, to be precise.

So I’ve been considering a suspension upgrade for some time. The 7r suspension seems to pale in comparison to the performance of the newer bikes, if not in performance, then at least in adjustability.

Two winters ago I completely rebuilt both of my front forks only to find that one now has a slow leak (probably due to me attempt to install the seal without the proper tools. Lesson learned.) I also need new tires.
Rather than purchase the parts to replace that same seal again, and spoon new Q2s onto my 7r wheels, I’ve decided that if an upgrade is to take place, it may as well happen now.

I’ve decided to go with a full gen 3 (2008 – 2010) zx10r suspension front and rear. This will include forks, wheels, swing arm, shock, brakes and rotors (along with the peripherals). My bike will essentially be a 7r from the frame in, and a 10r from the front triple forward, and the swing arm pivot bolt back.

I’ve been collecting the components necessary for the swap (minus any custom spacers/ fab stuff) since early May and have tried to be patient. I got really lucky on a couple finds, and not so lucky on others (had to pay $$$). It all came down to availability and time frame.
Let the fun begin:





















The real kicker: Gen 3 forks with Race Tech G2r cartridge kits already installed. Fresh from Race Tech with zero miles on them. I am unworthy.



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Holy phuck there's someone out there giving a damn about this thread!


:lol

Thanks, Lee. I was beginning to wonder.
Already over 3600 views and you think nobody's watching, that's funny. :rolleyes
Sometimes build threads get lurked more than you realize. I love the amount of info and details you have posted. Don't stop.
Already over 3600 views and you think nobody's watching, that's funny. :rolleyes
Don't mind me, guys; I was tired.

If I ever do that again just tell me to shut up and get back to the garage.
I haven't been around for a while, but that is the usual thread I check :rolleyes
keep up these updates!

and BTW, it looks great. and iirc, the 08 zx10 shock is 338mm, as opposed to our 350mm.

FWIW, 636 dogbones are about 6mm shorter, which should give about half an 1.5 cm in tail height (iirc the result of the leverage ratios..).and equal to about 4mm equal of shock height.

Avi
Good info. I almost tried my gfs spare zx6r dog bones before I had my buddy make the custom ones, but I wanted just a bit more room for adjustability.
2
Chain is on and set to tension. Everything's tightened up. Forgot to mention that I picked up a chain guard on eBay, pictured here.





Front brakes are back on with the OEM brake caliper bolts I ordered. They were dragging a bit the other day, wasn't sure why so I pressed the pistons back into the caliper housing, bolted them up, and reseated the pads. They work fine now.

In my opinion, suspension and brake system is ready to go (at least for a test to see where we stand). In the next few days I'll probably throw at least the tank back on and take her for a spin around the block just to see what's up and go from there.
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Was just thinking about this:

To my knowledge, I'd be the first person on this forum to complete a full Gen III zx10r suspension swap (front and rear) onto a '96+ (P model) zx7r.


If this is not the case, please speak up. I'd like to hear about your experiences with the conversion and your thoughts post-conversion.

I already notice a front end difference just holding the brakes and pressing forward onto the front forks. The stock 7r forks seem quite unforgiving in comparison. Rear suspension seem comparable at this point but it's still waaaaay too early to tell.
Was just thinking about this:

To my knowledge, I'd be the first person on this forum to complete a full Gen III zx10r suspension swap (front and rear) onto a '96+ (P model) zx7r.


If this is not the case, please speak up. I'd like to hear about your experiences with the conversion and your thoughts post-conversion.

I already notice a front end difference just holding the brakes and pressing forward onto the front forks. The stock 7r forks seem quite unforgiving in comparison. Rear suspension seem comparable at this point but it's still waaaaay too early to tell.
Might as well put the airbox on too :rolleyes

Take a video while you're at it :evil
Looking good, The progress on your bike has motivated me to get some more done on mine, The main hurdle I was avoiding on mine was the wiring, Mainly because I am very fussy especially when it comes to something like the wiring, I managed to tidy up/shorten some more today so it can be tucked under the tank now with the bike being a naked/streetfighter style bike, I should be able to finish off the rest tomorrow & finally get the freshly painted tank back on & see how it looks

I have not seen an L model with theZX10 front & rear conversion like mine either?

I like he clash of the old style paint scheme & the modern suspension & wheels on this, Looks to be sitting low in the rear too, Cant remember where I got this pic?>
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I love this threat with all the informations which you and the others included. Making me think what to do with a J or L Modell as base.

Please be as detailed with your informations what are your findings at the test raides !

When i am thinking about the big difference which one single click at my ohlins makes while trying to find a setup for different tires it should be more then just "different" with forks and swingarm changed....
Looking good, The progress on your bike has motivated me to get some more done on mine.
Thanks, that's great.

I have not seen an L model with theZX10 front & rear conversion like mine either?
I believe Bullit has an L model with a complete 10r suspension swap. Perhaps he can correct me if I'm wrong. Not sure what Gen 10r components though.
I know the bike you are talking about now, I dont like red but it is a damn nice bike>
http://www.zxforums.com/forums/zx-7r-forum/55543-zx7r-up-grades-zx10r-parts.html

& for those that have not seen it, Some info on the rear shock & a bit of a of a guide on the battery mount mod for the L mod I posted>
http://www.zxforums.com/forums/zx-7r-forum/60578-zx7-zx10r-rear-shock-swap-what-year-zx10.html
I know the bike you are talking about now, I dont like red but it is a damn nice bike>
http://www.zxforums.com/forums/zx-7r-forum/55543-zx7r-up-grades-zx10r-parts.html
Yep, that's the one. I believe he used an '04-'05 suspension as well.


I notice that many opt for the earlier gen zx10r (or 6r) swing arms. I just don't like the way they look quite as much, particularly on the chain/sprocket side. That's one of the reasons I went Gen III, even if it is a little harder to get things to clear and so on.



& for those that have not seen it, Some info on the rear shock & a bit of a of a guide on the battery mount mod for the L mod I posted>
http://www.zxforums.com/forums/zx-7r-forum/60578-zx7-zx10r-rear-shock-swap-what-year-zx10.html

I remember this. That is some NICE work. Your patience and attention to detail will pay off in the long run. It looks like you have access to some nice equipment as well. That battery tray doesn't look like it was made with a hack saw and a bench vise. :lol

Again, great job on that. Have you started an official "build thread" for your project?
Bodywork is back on.

Took the time to set the front and rear rider sag (with the help of my lovely assistant). Both are set at approx. 35mm.


We took the time to weigh the bike. I forgot my sheet with my initial zx7r overall weight, so I don't have that for comparison but today she weighed in at 460 lbs. with half a tank of fuel.

With myself seated in riding position on the bike my scales read 310lbs for the front and 320lbs for the rear, so I've got a reasonably even weight distribution.


After that, went out for a short shake-down run around the neighborhood. She feels different but good. I honestly couldn't enjoy it, I was too busy paying attention to the drive train and brakes, making sure everything was working correctly (no weird vibrations, noises, disturbances, etc.).

I found a few odds and ends to tidy up. I still need to put my Dynabeads in the tires. Bike needs wiped down. I'd like to put my wheel stripes on as well.


Hope to have some nice pics for you guys soon.

:cheers
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Congrats!
I've worked out a few bugs and will most likely throw my wheel stripes on today and take a few photos... Then go riding. :smile


Now that I've eliminated the speedo drive from my bike via the 10r wheels, I'm considering aftermarket gauges since I have no speedometer or odometer at the moment. I really like this model from Koso:




This mod will most likely take place over the winter (due to price plus riding season time constraints). I upgraded everything else, may as well do the gauges too, right?

:dunno
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I remember this. That is some NICE work. Your patience and attention to detail will pay off in the long run. It looks like you have access to some nice equipment as well. That battery tray doesn't look like it was made with a hack saw and a bench vise. :lol

Again, great job on that. Have you started an official "build thread" for your project?

You would be surprised, The sheet was cut out with a grinder by hand (Using a thin disc) but the battery tray was folded at a fab shop down the road, Only took about 5 minutes to sort out the folds, Lots of working out & measuring & double checking though to get it spot on before cutting, I am a fussy prick on a small budget!
Now that I've eliminated the speedo drive from my bike via the 10r wheels, I'm considering aftermarket gauges since I have no speedometer or odometer at the moment. I really like this model from Koso:




This mod will most likely take place over the winter (due to price plus riding season time constraints). I upgraded everything else, way as well do the gauges too, right?

:dunno
Have a look at the Koso DB-02R also, I like the simpler layout & shape (I dont like the speedo's with the visible fuel gauge that cant be used, I dont really feel like fitting a fuel gauge sender setup in the tank), + the cheaper price tag is a bonus, I am trying to find one for another bike with the blue backlight? I can only find them with the typical white background>

http://www.kosonorthamerica.com/kos...b-02r-digital-lcd-meter-streetrace-version-4/

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Have a look at the Koso DB-02R also, I like the simpler layout & shape (I dont like the speedo's with the visible fuel gauge that cant be used, I dont really feel like fitting a fuel gauge sender setup in the tank), + the cheaper price tag is a bonus, I am trying to find one for another bike with the blue backlight? I can only find them with the typical white background>

http://www.kosonorthamerica.com/kos...b-02r-digital-lcd-meter-streetrace-version-4/


I don't like the idea of a useless gauge either. I could care less about knowing how much fuel I have left, that's what my odometer is for.

I really don't like the bar-style tachs, though. I would really prefer a needle-style tachometer, which is why I like the Koso. I may have to see if they have a suitable option without a fuel gauge... I suppose I could look past it too. I'd just wire it to show "full" all the time.
Tied up the loose ends. Set my tire pressure. Took the bike out in front of the garage, put it up on the rear stand, and had my gf take a bunch of photos with her good camera.

Pics in just a bit, gents. :cheers
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