Front end

From the Frequent Mods on TLP, this might help:



Recipe to installing GSXR forks with a dash of Traxxion Dynamics Zest

Ingredients:

1 x set of 2006 GSXR1000 forks (ebay - $200 shipped)
1 x set of 2006 GSXR750 calipers (ebay - $40 shipped)
1 x 2008 Hayabusa front axle with spacer (ebay - $50 shipped - if the axle didn't come with one you'll need to get one from Sam)
2 x lower triple tree spacers (Home Depot - $10 - also available from Sam)
4 x M10x70x1.25 bolts (Yamaha engine mounts - $10 - also available from Sam)
2 x Sam's Rotor spacers (TLP - PM Sam for price)
1 x 2006 GSXR1000 carbon fiber front fender (ebay - $139 mdi-carbonfider)
4 x 5mm brass caliper spacers with lips (locally made - priceless - also available from Sam)
2 x set of new 2006 GSXR750 brake pads (ebay - $139 - not shown)


Optional to enhance the recipe:
1 x set of 2006 GSXR1000 Traction Dynamics valves
1 x set of TL1000R springs and spring spacer


Disclaimer: I highly recommend you get this done by a Traxxion Dynamics rep!!!!!

Foreword:
I highly recommend servicing and inspecting the internals of any forks bought used, whether it is ebay, CL, or anywhere else. It is extremely important to inspect your inner forks and have them re-polished if they are damaged.
Ingredients used to service the forks:
K&L oil seals
Amsoil #5+#10 fork oil


The homemade ingredients:
The lower triple tree spacers/shims can be home made. Home Depot currently carries a 1'x2'x0.019" sheet metal with which you can cut out 2 pieces of 40mmx170mm. You can roll those very easily with something that is already round.
Picture of the 1x1x0.019:


All you need to do is cut a 50mmx165mm piece and file down the edge to avoid scraping. You can roll it by hand with something round like a pop can.

The caliper spacer were made by none other than our beloved Minnesota local Traxxion Dynamics rep, Glenn:


No instructions here other than buy it from Sam or contact me if you want Glenn to make them (I don't know anyone's price but Sam's are prob cheaper since he's been doing them for a while)

Instructions:
Remove the front wheel and OEM front fender

Measure the distance from TOP OEM forks to TOP triple tree surface. You'll need that to keep the same geometry. Let's call this "fork offset"


Remove OEM forks and clean the inside of the triple tree

Remove the OEM calipers and let the lines dangle (you probably should let them dangle over a container)

Remove the rotors and place the Sam's rotor spacers and install the OEM rotors back on.


Install the triple tree spacers

Inspect that the spacer installed does not overlap on itself. If it does, you'll need to remove it and cut out some more. Don't forget to file down the cut.

Install the new forks. Since my 2006 GSXR1000 forks are 3mm LONGER than OEM TLR forks according to Sam's chart, I'll add it to my "Fork offset" (note this is approximate for now and you'll need to figure out your own difference: refer to Sam's Fork chart)


Tighten up ONE bolt on the triple tree to pinch ONE fork. Install the front axle in a manner that it does not bind and you are not forcing the axle in. Move the free fork up and down if need be.


Once the axle is inserted, you should be able to turn it without much friction.
Tighten ONE bolt from the fork that was still free.

Tighten all bolts on the forks using torque specifications

Remove the axle

Install the front fender and front wheel.

Install the calipers spacers


Install the calipers (with the old pads)


Install the brake lines

Bleed the lines (this is why I installed the calipers with the old pads)

Install the new pads.
Note in the picture one pad has ridges. If you buy pads that do not come with those ridges, I suggest you make them. A metal saw blade will do the trick.

Done! :thumbup easy as cupcakes, right? :devious

Nom-nom-nom!