2005 ZX10r USD Conversion.

[kenmoore]

Been on holidays surfing up the North Coast and a heap of parts have turned up whilst away.

I don't want to Joanna myself but I think I have everything.

1- A set of 2005 USD forks out of a ZX10r with new seals and oil

2- A Yana Shinki top tripple that I bought of Mikstr in Canada bored out to 50 mm to take the forks.

3-'A 2008 CBR600rr lower tripple

4- A set of 2009 Triumph Daytona 675 Monobloc radial calipers that are currently at the machine shop having 10 mm taken of the shoulders to be compatible with the standard discs.

5- A set of Apex bars that I also bought of Mikstr and he very generously threw in the required front axle spacers and a set of Zcoo pads for the Triumph calipers

6- A new Zx10r front fender that I am in the process of painting satin black to match my braced swinger

7-A new set of tapered steering stem bearings from all balls

8- A triumph Daytons 675 brake master cylinder and lines as well as a fluid reservoir. ( I have ordered a cnc reservoir that has yet to turn up)

9- Shortened caliper bolts to accomodate the machining of the shoulders on the Triumph calipers.

I have chosen to go with the ZX10 forks because I can retain the original front wheel , rotors and axle.

While I am at it I am going to heat wrap the pipes and fit some white instrument faces that I got from Poland.

I will hopefully start the work tomorrow and of course I will post plenty of pics for those interested.

I have wanted to do this for a long time now and hope that it improves the handling.

If all goes well there will be a fully sorted front end for sale on here soon.

[vtrstormer]

That's an extensive list mate I hope it all works out.

Are you having the front forks modded to suit your weight?

[kenmoore]

At this stage I intend to fit them up, reset the sag and ride to determine what I want to do .

I have read a lot about these forks, some good and some bad.

Most people who have them just play around with oil volumes and settings.

Some say that they are harsh and fit less oil to increase their travel.

I am thinking that at the very least a new set of springs will be in order.

Main priority is to get them fitted up .

I also have a HRC quick action throttle tube to fit along with all the other stuff.

About to go to the cave and start measuring up .

Also wondering if I am going to have to move the radiators to allow for clearance on the lower triple as it is a lot beefier than the original.

Will take some pics as I go.

[vtrstormer]

Mate I hope it works out. They suit the Beefier looking fork tubes and triples.

You will love the quick action throttle tune as well. I have the R6 tube and it's bigger than the HRC one which means even quicker action and I love it. The only thing you need to be mindful of and I'm still yet to change mine is the slack in the cable needs to be set right. I used to ride with no slack in the cable with the standard tube and that's how I have set it up now but with the QAT now installed it's very on offin it's operation so I will need to give it a tiny. It back

[kenmoore]

Trial fit of triples and bars after doing the fork oil.









The gold looks good against the Red !



Just waiting for the calipers to come back from the machine shop now.

Will start dismantling for fitment now.

More pics to follow

[kenmoore]

Quick action throttle tube,



Overplayed white tachometer face to see what it looks like, also have speedo as well.



Now to carry on with painting the front guard and start pulling things apart.



Raining here and no surf so a big day in the Cave hopefully.

[vtrstormer]

They look the goods mate cannot wait to see the final product

[kenmoore]

They are in,





Now for all the fiddly stuff !

Also started wrapping the pipes, bloody safety wire I have is too thin , have to get some thicker stuff.

Will paint the front guard tomorrow, it is prepped and ready for painting.

Still have to put the pads in the calipers that came back from the machine shop earlier this arvo.

All in all, not to hard to do.

Happy with the way they look, might have to muck around with the steering stops and relocate the radiators a bit towards the rear.

Will post more pics as I go.

[kenmoore]

Trial fit of front wheel. I think I have the spacers in the wrong way, will sort it tomorrow!



Happy with the progress so far, have also fitted the pads to the calipers ready to go on.

[kenmoore]

Front wheel all sorted, yes the spacers were arse about. Now everything lines up!

Fitting the quick action throttle.

[vtrstormer]

Will the front end up sitting lower than stock? And Did you get full lock

[steve400]

Ken ive got some stainless cable ties laying about, theyre silver but nothing some black (or whatever colour you want) engine paint won't fix. Happy to post you some if you like, let me know if you're interested and how many you're after. To tighten them there's a special tool, but cabac charges $220 for it so when I'm not at work I just roll the end around a screwdriver and just keep rolling, seems to do the trick.

I like shiny pipes, I think they're beautiful and I never want to cover them up, but a nice wrap can be very tidy to look at. My cb400 has matt black headers and mid pipe and are dying to be wrapped... might get some of this Kevlar shit and give it a go.

Anyway let me know if you want some stainless steel ties and I'll see what I can do.

[kenmoore]

Hey Steve,

Thanks for the offer mate, I got some S/S ties with the wrap and am going to lock wire the rest.

Like you I like shiny pipes too but thought that I would try the wrap for a different look.

Who knows , I may not like it!

Today I just tinkered a bit as I had some personal stuff to take care of before I return to work.

The calipers are fitted, now I have to work out the brake lines, drill some holes in the bars to take the switch gear( won't do this until I line everything up ) and reassemble the air filter etc after fitting the quick action throttle and lots of fiddly shit .

A bit disappointed that my brake lever does not fit the radial Triumph master so I have had to order another one from SDR. For the time being I will have to use my VTR master, may not be ideal but I am an impatient prick and will want to ride the bike to experience my handy work and then fit the Triumph master when the lever arrives.

All up I have spent about a grand doing this mod.

I hope it will make the difference that I am seeking. Another problem will be the back shock so currently I am on the lookout for a decent new or secondhand shock at a reasonable price as I am expecting the bike to be unbalanced due to this modification.

More pics to follow as I go.

[kenmoore]

VTR,

I don't know wether it is lower as I haven't started measuring up yet. I took measurements before I pulled the standard front end and will let you know.

As far as the lock goes I will have to mod the stops on the left side to get full lock there but I will trial fit the fairing before I do that. The right seems O.K.

I also need to refit the HISS somewhere and work out where to put the horn as well.

Just as expected , lots of little details to take care of.

All part of the fun I guess!

[kenmoore]

Took some measurements, definitely much shorter in the fork legs.

Looks to be about 200mm, a lot I think.

Maybe the 6mm shim wil become obsolete through this mod !

That would have to "load " up the front end wouldn't it ?

The Apex bars have helped me to get the same measurements in relation to bar height and position but look a little strange in my opinion, the fairing should hide them.

Pics to follow.

[kenmoore]

Back at work now so the progress will slow somewhat.

Have fitted the QAT and fitted one of the bars to the original position, looks funny but the fairing should hide most of the bars.

Front fender is now painted and will rub back and give a final coat this week.



More to come.

[kenmoore]

Well some progress at last,

Brakes fitted and bled, front guard painted and on, bars lined up and switchgear fitted.

Exhaust heat wrapped and refitted.

Now to do the instrument faces!



More pics to follow.

[kenmoore]

Well,

Just went for a short ride around the Village I live in.

Can definitely feel the difference with the forks and brakes.

The quick action throttle is easy to live with, makes the bike feel more powerful for some reason!

Happy with the result, now to do some fiddling with the forks and reposition a few things.

So far so good.

Next weekend will be the test.













Need to tidy up some of the safety wire on the exhaust wrap and waiting for some bar ends to arrive.

The finished product bar a few adjustments.



Very happy with the result, now the fun begins.

[kenmoore]

Well,

I couldn't help myself and as it hadn't rained for a couple of hours I went for a blast over the mountain to Kangaroo Valley.

Hallelujah, what a difference . Absolutely a different bike, the front end is so planted and the brakes are just incredible. I had F4i calipers, braided lines etc and there is no comparison.

Just a totally different bike and I haven't even done the sag yet and shock of all shocks(Pardon the pun) the back still feels great.

One happy camper and a must do mod !

Now I need to file the lock stops a bit more, work out what to do with the HISS and ride and enjoy !

[binny]

Great work mate.

[vtrstormer]

Mate that's a great result and if it works as good as you say and great upgrade to boot.

Where there any major issues with fitment of the forks and triples etc.

[kenmoore]

Dare I say it I got a lot of info from Mikstr on the US ( I like to think of it as ) sister site.

Obviously I researched this mod as I didn't want it to go pear shaped.

The biggest influence in using the ZX10 forks was the ability to be able to use the VTR axle , wheel and discs. A major $ saving exercise there.

The rest was just a matter of sourcing all the necessary parts and once I had them it was game on .

The end result was worth it. Bike off the road for a week and a half and apart from a trip to the Auto Store and Wemoto ( I needed some speed clips to assemble the front fender, a longer brake line from the master to the calliper and some new flange gaskets for the exhaust) for the only parts I didn't have on hand everything went smoothly.

Some small adjustments here and there and it should be all good.

Will share my thoughts on this mod as I go. All up cost me about $1100- and as I love the way the Storm goes it turns out to be a very cost effective way of acquiring a bike that you love that is just that little bit better .

Thoughts please,

I don,t like the way the front fender is mounted.

The vertical uprights that attach the fender to the forks looks too chunky for me and I think I will trim it up by reshaping it.



Cheers

[binny]

Yeah agreed. It does look a bit chunky.
Is the front sitting up a bit higher than stock or is it just the angle of the photo?

[kenmoore]

Thanks binny,

It's the angle of the photo , It's in my drive and I live at the top of a hill.


Helps when you have to clutch start a bike because they haven't been used.

The front is definitely shorter according to my measurements. Not by much though!b( May necessitate removal of the back shock 6mm shim. It felt a bit light in the front a couple of times over the mountain! Not that I mind that )

Won't be happy until I fit the Triumph radial master that matches the callipers. Waiting for a brake lever! have the remote reservoir.

Tinker tinker .

[vtrstormer]

I like it. The chunkier fork legs suit the bike and look much better than the stick fork legs. The front fender does look a little off but I think once you got used to it it would be ok...

Question if the front is shorter why the need for a longer cable? This was a question I had sometime ago when I wanted to do my front end. I had just bought all new braided lines and then had a cbr954 front end become available and was wondering if I could use all my new lines?

[kenmoore]

That's a good question,

I am still trying to work it out myself.

I will take some pics.

The original Hel lines were 1 piece that bolted to the lower tripple then split of to each caliper. The line from the master to the splitter was the problem. Not long enough to enable the caliper lines reach the caliper and it couldn't be mounted on the tripple.

I ran a longer line straight to the right caliper , used a double banjo and ran another short line over the fender to the left caliper.

Hope that makes sense, when I take pics it will.

Cheers

[kenmoore]

Tinkered with the set up today,

Left bar was lower, I used Vernier Calipers to get it right. The Apex Bars make it easy to get everything lined up due to their adjustability.

The bike feels better sitting on now !

Bloody pissing down rain here at the mo, always happens when I do something major to the bike.

I reckon I am 90 percent done and won't regard it as done until I fit the Triumph master for the front brakes.

Will post pics when done.

[kenmoore]

Went for a ride up to the Neriga Pub this arvo.

What a revelation.

Totally different bike and handles great.

The whole Bike (Now I know why I kept it as a long list of bikes transited through the Man Cave, some mine, some not but they might as well of been! ) feels more settled and just tracks through the rough stuff.

Very enjoyable to ride now.

The brakes are ridiculously good so I may just leave the standard master as they have plenty of feel and are now 1 finger jobbies!

Just a totally different experience, corner speed is up by heaps, I will have to be careful.

[steve400]

Sounds like a great mod ken. Looks a treat too - it's a big bike and I always thought the stock shocks looked rubbish but these chunky gold ones are the business.

You're a braver man than I, i reckon I'd have to double your budget to make this happen for me. Might be better off investing in another bike, but I just love the v twin rumble...

[kenmoore]

It is a great mod and cheaper than getting another bike.

This mod makes an already good bike better.

Currently off the road as one of the forks I bought has a slight kink in it that caused the fork seal to blow.

Happened on the third ride as I started to explore the difference.

Have another fork on its way from the States. Hopefully it gets here quickly. It's the right upper gold tube , just a very slight kink, but enough to cause the problem.

Major pain , hopefully the new one is O.K.