CF650nk USD fork conversion

[Wald0]

So as I do like the bike and how it handles I miss little that front end is not that good and little soft for me, and then it hit me! USD conversion....

As our bike is modeled from ER6 that was great way to start this little project.

Searching Internet it seem I had 2 main Options. ZX10r or ZX6r, ZX10r are bigger as top are 50mm and bottom 54mm but uses same axle as our bikes, ZX6r are slightly slimmer, 50mm and 52mm but are longer and will come out of top triple and unless you plan to use clip ons should go ZX10r route.

that on mind started to source all items what I would need.

you will need following Items.

1. Forks from Kawasaki ZX10r 2004-2005 and axle +wheel spacers
2. Lower triple tree from Kawasaki Versys 2008
3. Top triple from kawasaki Z750 2008
4. Calibers from Zx6r or Zx14r as they are same.
5. Front fender from Zx6r

Reason for number 1 is that it has the same axle thickness as our 650, so direct bolt on. If you would go 2006 onwards forks or zx6r forks you would have to machine front wheel to take larger diameter bearings.

Number 2, It had same diameter and lenght as our bikes steering stem. so it will just bolt on, But Kawasaki versys uses USD forks what are 52mm in clamp area and ZX10r are 54mm so it does mean you will have to ream out 2mm. if using ZX6r forks (what are longer than Zx10r by the way.) you can skip this part. I did have to add little extra material to steering stopper on frame as on right side of the bike it did connect slightly to radiator cap, and left side the frame.

Number 3, Idea of this was to keep original steering lock as they do in Er6 bikes, but I did not do my research in this part as it seems ignition is very different in ER6 bikes.
So steering lock will not work. That said you can use also -08 Z1000 or even Z1000SX top triples.

Number 4, Calibers.. Zx6r as they also have 300mm discs.

Number 5, Fender... you can use ZX10r.. but I think ZX6 (2007) look better and it was available.

Problems what I encountered where following
1. Ignition. can't get steering lock to work unless welding new stops on frame
2. While Wheel and axle width is same as ZX10r wheel and Kawasaki Er6 disc offset is different! so adapters have to be made!
3. Using OEM headlight assembly, you will have to cut and build own brackets, as if connected normally it will sit too much out.

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[Wald0]

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Out of old and in the new ones.
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Direct bolt on, have to ream 2mm so it can accommodate larger diameter of ZX10r forks.
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Had to weld little more material to frame part so forks would not hit radiator cap and frame. about 2mm
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Ignition, I did take about 2cm of from top triple so ignition would mount higher.
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Spacer for the discs.

[alaskacf]

You have any before and after pics yet?

[Wald0]

You have any before and after pics yet?

I do have few, but maybe I could have done a better job documenting this..


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[martislash]

Is this the simplest way to put upside down forks? thanks!