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Project: Suspension Upgrade

59223 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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Damn nice, Thats gonna be a whole lotta fun, Might take a bit to dial it in but you should notice the weight reduction
Damn nice, Thats gonna be a whole lotta fun, Might take a bit to dial it in but you should notice the weight reduction
Thanks.

It feels weird right now. I was turning her around in the street to park the bike and I had to put a foot down, which is unusual. Gonna take some getting used to.
Wheeeeeeeeeeeeeeew!

Turned out awesome, dude!
Beautiful work. That bike looks about 5 years younger. :crazyloco
just catching up and it looks great!:clap

did you end up modifying the subframe?
Wheeeeeeeeeeeeeeew!

Turned out awesome, dude!
Beautiful work. That bike looks about 5 years younger. :crazyloco
Thanks, guys. :smile
just catching up and it looks great!:clap

did you end up modifying the subframe?

Thank you.


No, I didn't, at least not yet. It may not need it. Once I installed those dog bones and raised the rear to an appropriate height I really gained quite a bit of clearance. On my first shake-down ride I tried to go over as many bumps and dips as possible so as to get the swing arm to bump the frame if it was going to and it never did.

It's hard to explain but the side of the swing arm is actually tapered at an angle. If it were to hit my sub frame, there on the right side where it's close, it would only do so about 1/4 way down the swing arm, so there's actually more room to move there than previously expected at a glance.

It's one of those things that I'm going to have to feel out. I should be taking her out for a better shake-down run today. Last time I just ran around my neighborhood for a bit. Today I'll try a few back roads and such. I'll report back.
Wheeeeeeeeeeeeeeew!



Turned out awesome, dude!
You know I am a bit of a purist when it comes to these things....but I kinda like it. I was dubious at the start. keep us posted on the follow up.

Do you think that this WSB kit swinger that I am being offered makes my rear end look to big?
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Do you think that this WSB kit swinger that I am being offered makes my rear end look to big?
Yes.... so you should let me have it :p
Thank you.


No, I didn't, at least not yet. It may not need it. Once I installed those dog bones and raised the rear to an appropriate height I really gained quite a bit of clearance. On my first shake-down ride I tried to go over as many bumps and dips as possible so as to get the swing arm to bump the frame if it was going to and it never did.

It's hard to explain but the side of the swing arm is actually tapered at an angle. If it were to hit my sub frame, there on the right side where it's close, it would only do so about 1/4 way down the swing arm, so there's actually more room to move there than previously expected at a glance.

It's one of those things that I'm going to have to feel out. I should be taking her out for a better shake-down run today. Last time I just ran around my neighborhood for a bit. Today I'll try a few back roads and such. I'll report back.
with all the work you put into it, I am thinking just buy a 10r and fit the 7r fairings!
same results!:crackup

but it won't be mine, or your 7, right?

still waiting for the ride report
You know I am a bit of a purist when it comes to these things....but I kinda like it. I was dubious at the start. keep us posted on the follow up.

Do you think that this WSB kit swinger that I am being offered makes my rear end look to big?


No way! The 7r could use some rear end girth. That's why I wanted to swap swing arms in the first place (plus lighter weight, of course). The stock swing arm just looks too thin for a bike that's so beefy, imo.


Going out on a limb here; I'm guessing you paid slightly more for that than the $70 I paid for my Gen III 10r swing arm... Call it a hunch.
with all the work you put into it, I am thinking just buy a 10r and fit the 7r fairings!
same results!:crackup

but it won't be mine, or your 7, right?

still waiting for the ride report

The amount of time and effort is retarded, right?... I know. :angry


I have a bunch of things to take care of around the house. I'll probably take the bike out early this afternoon.

This is how the next generation 7RR should have looked had Kawasaki continued to develop it, too bad they stopped cold in 97. As usual, nice job!
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This is how the next generation 7RR should have looked had Kawasaki continued to develop it, too bad they stopped cold in 97. As usual, nice job!
Thanks, AZXRider.

You're right, all we can do now is try to modernize as much as possible... Unless you're a purist. I have to respect the guys who take the time to restore these things to showroom condition.
Just got back from my first decent ride on the bike since the front and rear suspension installation. Things went really well, so well that I extended the ride a bit. Didn't get too crazy with any cornering (fresh tires) but I tried to push the suspension and brakes by accelerating hard, braking hard, braking hard over bumps in the road (intersections), intentionally hit a few potholes and hard dips to check the swing arm clearance (no issues thus far).

This thing turns in much quicker now. I'm not used to it and I find it catches me by surprise. Very little input at the bars translates to a more immediate reaction by the bike that still seems foreign to me. I'm used to having to work a little harder with the stock suspension.

Most immediately noticeable differences:

- Braking/stopping power
- Front suspension smoothness


This things stops REALLY well with very little effort at the lever. The front suspension is very smooth without being too vague, feedback seemed good.

First impression on the rear suspension is that it doesn't seem to be leagues different than the stock 7r rear shock and suspension. The rear brake seems to have improved, not that that is really much of an issue anyway.

It will take some time and quite a few more rides for me to really be able to form a better impression, but I'm quite pleased with all of the changes so far.

:smile
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The braking/stopping power difference is mostly due to the rotating (& overall) weight reduction, The stock wheels weigh a ton, Would be much easier to stop the ZX10 wheels, The modern brakes though would make it all feel much smoother

Need to hurry up & get mine on the road, mine is going to be way lighter overall too
The braking/stopping power difference is mostly due to the rotating (& overall) weight reduction, The stock wheels weigh a ton, Would be much easier to stop the ZX10 wheels, The modern brakes though would make it all feel much smoother
I figured this much, less rotating mass. Plus I'm running the 10r master cylinder/lever. Modern calipers and rotors can't hurt either.




Need to hurry up & get mine on the road, mine is going to be way lighter overall too

Yes, do! Also, I'll ask again, did you start an official build/project thread? If not, you should certainly do so.
2
This past Friday was my gf's birthday so we decided to go riding. The weather was perfect, about 78 degrees and sunny.

Since the last ride went so well I decided to push the bike just a bit further to see if I could expose any weaknesses (what I would consider to be 70% pace, on the street anyway).

She handled really well. Now some of the things that were more subtle at slower speeds. Braking, entering corners, and initiating the turn are all much smoother now. Before, with the 7r front end, braking for a corner and initiating lean could be a bit sketchy.

Again, these brakes are amazing. Between the lower rotating mass, upgraded calipers/rotors, and suspension, the front end just applies stopping force to the front tire really well. I'm required to use very little force at the lever.

As for the rear swing arm clearance, still no problems or any signs of bottoming out, and I went over some large dips, bumps, and potholes at high speed... No problems.

A few pics post-ride:







Still have a bunch of fork left on the front end for emergency braking and more aggressive riding.





This is what I mean when I say 70%, about a half inch chicken strip left on the outside of the rear tire (hard to see it but the edge is just above the small Dunlop "D>"). Had to take it a little easy yet, this is still only my second ride on fresh tires.


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Nice!
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