Author Topic: CB750 Dual disc front end swap (with GSXR1000/600/750 parts)  (Read 56292 times)

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Offline Industrial Cafe

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CB750 Dual disc front end swap (with GSXR1000/600/750 parts)
« on: January 07, 2010, 06:57:34 PM »
This whole thing started because my master cylinder "sweats" around the plunger.
I wanted to either get a rebuild kit or a new one. So I started looking online at that stuff and figured I'd upgrade to a better master.

Well they're expensive, and more than I want to spend on a single simple part. Then I stumbled across Squirleys 550
and it immediately set my pants ablaze with it's radness.


It was then that I decided I would research the crap out of how to fit that junk on my bike!

I'm making this thread with prices and details, in case anyone else wants to do it themselves.
I bought everything on ebay.
(I'm a cheap skate)

$10.50S/H=$15.00    2006 GSXR600 bent fork legs




the straightening is being done by frame straight in Tennessee for $140.00  :-\
$20.00S/H= 7.50     2002 GSXR1000 lower triple, filed off the casting rib, the stops, and polished 'em out.


$25.00S/H=$10.00   2002 GSXR1000 upper tree and clipons.


shaved, modified, and polished.


$30.00S/H=$10.00   2004 GSXR600 calipers and lines (same as a 750/1000 in different years)


$12.00  S/H=$13.00 2002 Hayabusa rotors -pair (comparison to OEM CB750)
(came in a big box lot of GSXR parts)


$2.50S/H=$4.46    2006 Gsxr1000 axle and a 15/16 bolt for use as a tool


$30.00S/H=$13.00   All Balls Racing tapered bearing set


$7.00S/H=$4.00   stainless 2.25'' T-bolt Clamps


$5.50S/H=free  2'' I.D. reinforced silicone intercooler coupler (cut 4 pcs)


$0.00S/H$0.00  3.75x20x0.25 inch aluminum plank for headlight brackets

done


$16.00S/H$6.50 GSXR1000 Front wheel bearings and seals (All Balls)


$10.50S/H$18.00 19'' Narrow Glide Harley Wheel


$10.00S/H13.00  GSXR1000 master cylinder


I still need to convert my speedometer over to electric and get some grips.

I'll tally it all up when I'm done.
We'll see if it was worth it, buying it all separately or not.

Total So Far: 433.46
« Last Edit: April 16, 2010, 06:34:05 PM by Industrial Cafe »
everything I say is pure speculation and
I have no idea what I'm talking about  ._.


                                    Marla              .:71CB750:.CAFE



Offline vanillagorilla

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Re: Dual disc front end swap (06 GSXR1000)
« Reply #1 on: January 07, 2010, 07:01:35 PM »
You hairy like animal!  ;D Nice work, bud. Someday... The VG is just gonna have to deal with stock suspension and brakes for a while... At least now I will have a step by step instruction manual! Knew you were good for something...
1978 CB750K 1976 Z1 2 Trail 90s



Offline Industrial Cafe

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Re: Dual disc front end swap (06 GSXR1000)
« Reply #2 on: January 07, 2010, 07:08:27 PM »
now for the stem problem, the suzuki stem is about a 1/2 inch too short so I cut it off and pressed in a 76 CB750 stem. (my 71 was a smaller diameter inside the tree casting and damaged as well)


had to heat it up and stretch it 1 mm to fit into the GSXR tree


pressed it in and here it is
from left to right-
     cut piece of gsxr stem
     tool to stretch the 750 stem
     tool to press it out
     and the done deal  8)



mock up so far.

« Last Edit: March 13, 2010, 04:28:08 PM by Industrial Cafe »
everything I say is pure speculation and
I have no idea what I'm talking about  ._.


                                    Marla              .:71CB750:.CAFE



Offline Alan F.

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Re: CB750 Dual disc front end swap (06 GSXR1000)
« Reply #3 on: January 07, 2010, 07:52:53 PM »
Subscribed!  Hey, you could probably do some grinding on that old busted lower tree and ebay it as a custom made fork brace...probably cover one of your purchases with cash from that.  Nice sniping btw.
-Alan
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Offline Industrial Cafe

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Re: CB750 Dual disc front end swap (06 GSXR1000)
« Reply #4 on: January 07, 2010, 07:55:43 PM »
possibly.
everything I say is pure speculation and
I have no idea what I'm talking about  ._.


                                    Marla              .:71CB750:.CAFE



Offline kopptl

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Re: CB750 Dual disc front end swap (06 GSXR1000)
« Reply #5 on: January 07, 2010, 08:55:51 PM »
so all you had to do essentialy is press out the gixxer stem and press in your 71 stem?  please elaborate!!! me reading this makes me want to try diong this to my 76" 750.
Thanks!!



Offline YogiBear

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Re: CB750 Dual disc front end swap (06 GSXR1000)
« Reply #6 on: January 07, 2010, 09:03:17 PM »
very cool concept! Im subscribed.  8)

1974 Honda CB750K4        1973 Honda CB500 Four



Offline Industrial Cafe

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Re: CB750 Dual disc front end swap (06 GSXR1000)
« Reply #7 on: January 07, 2010, 10:06:56 PM »
so all you had to do essentialy is press out the gixxer stem and press in your 71 stem?  please elaborate!!! me reading this makes me want to try diong this to my 76" 750.
Thanks!!
Just to clarify, I pressed in the 76 stem, the 71 had a strangely small end welded into the tree.

I had to grind the weld at the bottom and I cut the stem out (refer up to the pic with the vise in it)
      Then I pressed out the GSXR stem, you have to press it down through the bottom because it's tapered something like 29.8mm to 30.3mm. Also, it has a circlip at the bottom.
  
    Then I filed the inner seam on the 76 stem and put an oxy-acetylene torch to it to heat the steel stem to a nice cherry red.
 I pressed a carbide taper into it to stretch it to the right size, using a micrometer the whole time. (the 76 stem was 29.6mm all the way down, when I was done it matched the GSXR stem dimensions)
It was just dumb luck that the taper was the exact size I needed. I keep everything and it was in my toolbox.

I knocked the taper out and let it cool in oil, then I heated it up again just so it would be 'warm' (not sure why) and pressed it into the GSXR tree.
   It was a good hard push on a 20 ton H-press and it ain't movin now.

that's really all there is to it.
the only reason I cut the GSXR stem short to begin with was to make it easier to work with.
« Last Edit: January 11, 2010, 12:00:09 AM by Industrial Cafe »
everything I say is pure speculation and
I have no idea what I'm talking about  ._.


                                    Marla              .:71CB750:.CAFE



Offline Industrial Cafe

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Re: CB750 Dual disc front end swap (06 GSXR1000)
« Reply #8 on: January 07, 2010, 10:14:43 PM »
I want to mount the headlight real low, and have the OEM gauges level with the trees when it's all done.

...I'll figure something out.
everything I say is pure speculation and
I have no idea what I'm talking about  ._.


                                    Marla              .:71CB750:.CAFE



Offline Shenanigans

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Re: CB750 Dual disc front end swap (06 GSXR1000)
« Reply #9 on: January 07, 2010, 10:53:28 PM »
more.  ;D
   This pretty much sums it up.   76' CB592 cafe. 69 750 project, 03 CBR954, 75 750 super sport.



Offline andy750

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Re: CB750 Dual disc front end swap (06 GSXR1000)
« Reply #10 on: January 08, 2010, 07:27:37 AM »
Im susbcribing as well - very good details!


good luck
Andy

(and thanks again for the parts ;-))
Current bikes
1. CB750K4: Long distance bike, 17 countries and counting...2001 - Trans-USA-Mexico (CB750K4), 2003 - European Tour (CB750K4), 2004 - SOHC Easy Rider Trip (CB750K4), 2008 - Adirondack Tour 2-up (CB750K4) , 2013 - Tail of the Dragon Tour
2. CB750/810cc K2  - road racer with JMR worked head 71 hp
3. VStrom DL1000 2003

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Offline domer

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Re: CB750 Dual disc front end swap (06 GSXR1000)
« Reply #11 on: January 08, 2010, 10:32:17 AM »
any particular reason you chose the gixxer front end? kinda curious about the disk mounting too....



Offline grandelatte

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Re: CB750 Dual disc front end swap (06 GSXR1000)
« Reply #12 on: January 08, 2010, 10:42:06 AM »
kool project!



Offline Industrial Cafe

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Re: CB750 Dual disc front end swap (06 GSXR1000)
« Reply #13 on: January 08, 2010, 11:17:01 AM »
any particular reason you chose the gixxer front end? kinda curious about the disk mounting too....
well my master was going to need a rebuild, then I thought "hey I want better brakes" -and doing a dual disc on my 71 front end was going to be um ...fun?  but it would still have the old 'stiction' forks on it, and the braking wouldn't have been as good as it could be.
   OH! and there's lots of adjustments to the suspension on the gsxr fork.
rebound, compression...
  
  also, I like the way it looks. The upside down forks with the 320mm rotors and 4 pot calipers. Mmm-Mmm!
I was going to do what Squirley did and use the 6 pot 02 type setup, but I got what I got and I'm going to work with that.


The disc mounting will be done on a Harley sportster wheel, I'll re-drill the rotor bolt pattern.
« Last Edit: April 16, 2010, 06:36:47 PM by Industrial Cafe »
everything I say is pure speculation and
I have no idea what I'm talking about  ._.


                                    Marla              .:71CB750:.CAFE



Offline Flying J

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Re: CB750 Dual disc front end swap (06 GSXR1000)
« Reply #14 on: January 08, 2010, 11:20:03 AM »
Im watching. 8)



Offline Industrial Cafe

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Re: CB750 Dual disc front end swap (06 GSXR1000)
« Reply #15 on: January 08, 2010, 11:23:12 AM »
in case you haven't seen his bike, this is Squirleys setup.
http://forums.sohc4.net/index.php?topic=34836.175
everything I say is pure speculation and
I have no idea what I'm talking about  ._.


                                    Marla              .:71CB750:.CAFE



Offline climbingaz

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Re: CB750 Dual disc front end swap (06 GSXR1000)
« Reply #16 on: January 08, 2010, 11:40:33 AM »
great project!



Offline ColinMc

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Re: CB750 Dual disc front end swap (06 GSXR1000)
« Reply #17 on: January 08, 2010, 11:43:55 AM »
Hows the lock to lock clearance? I did the same kind of swap on an old FZR1000 and had very little handlebar turning available because of the thicker fork tubes hitting the frame so much earlier...

Did the same thing you did, pressed the old GSXR stem out, cut the old FZR one out and pressed it into the newer lower triple.

I want to do this on a CB but with a Ducati Sportclassic front end so the whole thing can be swapped, spoked wheel and all.
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Offline Industrial Cafe

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Re: CB750 Dual disc front end swap (06 GSXR1000)
« Reply #18 on: January 08, 2010, 12:38:08 PM »
the lock to lock sucks, the fork tubes hit my tank, I need to put some bump stops in. 
Sooner or later I'll have to have a shop make me some trees with more trail.
One day, but as for now, it will work.

I wanted to get a Duc Sport Classic fork setup, but I don't have that kind of money.
everything I say is pure speculation and
I have no idea what I'm talking about  ._.


                                    Marla              .:71CB750:.CAFE



Offline kopptl

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Re: CB750 Dual disc front end swap (06 GSXR1000)
« Reply #19 on: January 08, 2010, 07:34:42 PM »
so in all reality,... this front end swap is not really that hard!? like time labor machinig?? just curious.... ur really making me consider doing it to mine come spring time!!



Offline Industrial Cafe

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Re: CB750 Dual disc front end swap (06 GSXR1000)
« Reply #20 on: January 08, 2010, 10:22:39 PM »
I don't think so.
not so far anyways.


I can't seem to find a suitable headlight clamp. the fork section I want to mount it to is 51mm
any ideas?
« Last Edit: February 13, 2010, 02:02:55 PM by Industrial Cafe »
everything I say is pure speculation and
I have no idea what I'm talking about  ._.


                                    Marla              .:71CB750:.CAFE



Offline Alan F.

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Re: CB750 Dual disc front end swap (06 GSXR1000)
« Reply #21 on: January 09, 2010, 07:44:56 AM »
Fork ears are probably out of the question for lock to lock reasons, but maybe a benjie style bracket will do for your headlight? it mounts to the lower tree and a semi-circle of barstock rises fron the mounting points up to the headlightt mounting tabs left and right. the headlight seems to float independantly of the fork tubes. it'll keep your tubes' gold color uncovered all the way up and might also be just what you need to get your clocks where you want them.  -Alan
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Offline Industrial Cafe

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Re: CB750 Dual disc front end swap (06 GSXR1000)
« Reply #22 on: January 09, 2010, 08:39:39 AM »
hmm,
I like the design but 110 bucks is more than I've spent on the entire swap so far.

the mounting points would have to be bent flat.
now if Benjie wants to be a pal, and stick one together that will mount flat on the face of the GSXR fork and call it "streetfighter headlight bracket" I'll buy that for $25 and put www.benjiescaferacer.com stickers all over my bike.
 ;) :D
waddya say Benjie?!  ;D ;D ;D

or, there is the option of making one like it myself, I think that would be more my speed.
« Last Edit: January 09, 2010, 09:13:50 AM by Industrial Cafe »
everything I say is pure speculation and
I have no idea what I'm talking about  ._.


                                    Marla              .:71CB750:.CAFE



Offline Alan F.

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Re: CB750 Dual disc front end swap (06 GSXR1000)
« Reply #23 on: January 09, 2010, 08:52:14 AM »
I'm not suggesting you buy one, just use the concept, my 92 Nighthawk uses a headlight support frame between the upper and lower triple trees that's independant of the fork tubes also, he didn't invent the concept (as usual) but his execution...and price, are top notch.
-Alan
Free Fork Swaps and Upgrades info parked at http://sites.google.com/site/alansdocuments/ 

My slow going 750K3 with swaps build http://forums.sohc4.net/index.php?topic=46082.0



Offline Industrial Cafe

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Re: CB750 Dual disc front end swap (06 GSXR1000)
« Reply #24 on: January 09, 2010, 09:07:47 AM »
I see.
   I'm not saying anything bad about the part or price, that's a good retail price for a unique stainless steel part, designed for specific duty.

 I just don't like spending money ;D
« Last Edit: January 09, 2010, 09:27:50 AM by Industrial Cafe »
everything I say is pure speculation and
I have no idea what I'm talking about  ._.


                                    Marla              .:71CB750:.CAFE