anyone know how swap forks?

Ming · 08-25-2009, 11:07 PM

So it seems pretty basic, but do any of you have any experience swapping forks? I'm going to be putting some 07 zx-6r forks on my 636 as soon as they arrive. My fork seals are toast, and bike will stay garaged until they get swapped.

Anywho, so I know if I do it myself I'll need to borrow a front fork stand.
Once I have the bike in the air do I just loosen the bolts on the top and bottom of the triple and drop em? then replace and tighten? Anyone have any ideas if they have a guide to line them up? Or how you can make sure that both forks are even and straight with the bike? Carl's quoted me $100 for the forks and $30 to swap rotors, but if this is easily something I can get done properly in my garage i'd rather do that. I just don't want to chance it and have my forks be all wack...

Waldo · 08-25-2009, 11:13 PM

Are the 07 zx-6r forks and your 636 a direct swap? Not all forks are the same size or use the same axle, spacers and wheels. If they are a direct swap then it is very easy.

Hoard · 08-25-2009, 11:15 PM

For my CBR you just have to take off the wheel/rotors ect. Then unbolt the 8 triple tree bolts. The forks drop right out.
As far as a guide to line them up.. I just used a tape measure before and after. Measuring from the top of the fork to the upper triple tree.

Ming · 08-25-2009, 11:15 PM

Quote:

Originally Posted by Waldo

Are the 07 zx-6r forks and your 636 a direct swap? Not all forks are the same size or use the same axle, spacers and wheels. If they are a direct swap then it is very easy.

yes its a direct swap. the parts I needed i ordered. forks, rotors, fender.
so how do you do it?

Waldo · 08-25-2009, 11:20 PM

Pretty much Remove and Replace. Do you have pinch bolts on one of your forks holding the axle?

CBRF2Old · 08-25-2009, 11:21 PM

The only thing I know about swapping forks is when I accidentally grab one of the short ones (salad?) from the drawer and then have to dig for one of the long ones (meat eater).

It really is pretty simple if all the parts are the correct size for the triple clamps etc. The big thing would be alignment. Run a string from the back tire (on both sides and assuming that the back tire is aligned correctly) to a point in front of the bike and measure from the string to the front tire. Also measure from the ends of the handlebars to a midpoint on the back of the bike to make sure that the bars are aligned. Tighten the bolts and u r good to go.
I have done this on the CBR (and found that something is seriously out of whack, i.e. at least two crashes.), but it is not hard to do. Let me know when you want to do it and I might be able to give you a hand with it.

Waldo · 08-25-2009, 11:24 PM

I can also give ya a hand

stubby · 08-25-2009, 11:24 PM

Check out Jason's write up on corporatesuspension.com it might help you out and it has a few pointers along the way.
http://www.corporatesuspension.com/s...w-to/forks.php

Ming · 08-26-2009, 12:05 AM

Quote:

Originally Posted by CBRF2Old

It really is pretty simple if all the parts are the correct size for the triple clamps etc. The big thing would be alignment. Run a string from the back tire (on both sides and assuming that the back tire is aligned correctly) to a point in front of the bike and measure from the string to the front tire. Also measure from the ends of the handlebars to a midpoint on the back of the bike to make sure that the bars are aligned. Tighten the bolts and u r good to go... but it is not hard to do. Let me know when you want to do it and I might be able to give you a hand with it.

I may need to borrow your fork stand, and if you are available yourself friday afternoon or saturday. (depending on when the forks get here.)

Quote:

Originally Posted by stubby

Check out Jason's write up on corporatesuspension.com it might help you out and it has a few pointers along the way.
http://www.corporatesuspension.com/s...w-to/forks.php

This actually cleared up a few things about alignment, which is what my main concern was.

and if either of you two could spare your fork stand this weekend (hopefully depending on shipping times) I'd be most grateful.

Cider · 08-26-2009, 08:22 AM

Stubby posted a good article, but I'll stress it again--be careful to torque the pinch bolts correctly. If they are too tight, you can actually bind up the springs, or possibly even crack a triple.

Also, before you torque the pinch bolts on the front axle, take the bike off the front stand and bounce the front forks a few times against the front brake. Finally, if you have clip-ons, test your steering lock-to-lock to make sure they won't hit the tank. If you do this while the engine is running and the revs change, the throttle cable is probably binding up.

stubby · 08-26-2009, 10:51 AM

Ming you can use the stem stand this weekend if you need it, although I don't know what pin your bike uses. If you could look on pitbulls website and see what pin you need, I will see if I have it. I had one that worked for Brandy's ZX6r but your bike might be different.

Ming · 08-27-2009, 01:10 AM

Quote:

Originally Posted by stubby

Ming you can use the stem stand this weekend if you need it, although I don't know what pin your bike uses. If you could look on pitbulls website and see what pin you need, I will see if I have it. I had one that worked for Brandy's ZX6r but your bike might be different.

Thanks stubby. can you bring it to work for matt to pick up thursday or friday? I just got my forks in today, and my rotors come in friday, so I should have it all together by saturday. My bike takes a #2 pin, so if you have one that'd be great. The #2T that fits a 06-up gixxer works as well. I won't have a fender on my bike when I lift it up, so if the #2T is all you got that will work just fine.

stubby · 08-27-2009, 01:20 AM

I think I have both #2 and #2T. I will double check. I don't know about bringing it to work tomorrow as Matt said he wanted to ride into work tomorrow. Could always make the 2mile journey home at lunch and pick it up though if he drives in.

Ming · 08-27-2009, 01:42 AM

Quote:

Originally Posted by stubby

I think I have both #2 and #2T. I will double check. I don't know about bringing it to work tomorrow as Matt said he wanted to ride into work tomorrow. Could always make the 2mile journey home at lunch and pick it up though if he drives in.

Cool. Thanks! And if home is out of the way, friday is fine. If Matt decides to ride both days I can come out and pick it up Friday. I get done @ 3pm. I'll talk to Matt in the morning also to see if he's driving or riding either of the two days.

Matt · 08-27-2009, 10:32 AM

Apparently the county has decided to keep me off of my motorcycle by chip sealing and taring every F-ING road there is out from my house off of Federal Way!! GRRRRRRRRRRRR!

Anyway, No problem I can drag it home for ya

I'm sure the roads will be a crapshoot for the next few days anyway. Stubbs: You comin in to work today or what?!? hehe Slacker

LazyJ · 08-27-2009, 10:37 AM

Quote:

Originally Posted by Matt

Apparently the county has decided to keep me off of my motorcycle by chip sealing and taring every F-ING road there is out from my house off of Federal Way!! GRRRRRRRRRRRR!

Anyway, No problem I can drag it home for ya

I'm sure the roads will be a crapshoot for the next few days anyway. Stubbs: You comin in to work today or what?!? hehe Slacker

yet another reason i have spent less time on my machine lately...

eager to see both 636's roll out some day....

Ming · 08-27-2009, 10:55 AM

Quote:

Originally Posted by Matt

Apparently the county has decided to keep me off of my motorcycle by chip sealing and taring every F-ING road there is out from my house off of Federal Way!! GRRRRRRRRRRRR!

Anyway, No problem I can drag it home for ya

I'm sure the roads will be a crapshoot for the next few days anyway. Stubbs: You comin in to work today or what?!? hehe Slacker

Yeah I know right?!?!

Thanks bro! I may get started on the forks tonight if you can get the stand from stubby. Then finish em tomorrow when my rotors come in.

Quote:

Originally Posted by LazyJ

eager to see both 636's roll out some day....

If all goes well I'll have everything together friday night. So I may be able to roll out for a ride saturday!

stubby · 08-27-2009, 11:32 AM

I will grab the stand at lunch so your secretary Matt can deliver it for you. Would you like any coffee or sandwiches when he comes home?

Did you still need to borrow the mity-vac for your brakes?

Ming · 08-27-2009, 11:36 AM

Quote:

Originally Posted by stubby

I will grab the stand at lunch so your secretary Matt can deliver it for you. Would you like any coffee or sandwiches when he comes home?

Did you still need to borrow the mity-vac for your brakes?

Thank you kind sir.

I won't be home til late, so maybe a night cap?
"I'll take Goose on the rocks please."
Matt just bought a bleeder so I won't need the mity-vac, but anything you think may help with maintenance I could use. (Still got to do, forks, rotors, fender, brakes, coolant, and for MMP am I missing anything else?)

stubby · 08-27-2009, 11:39 AM

I think you covered it all, as I think you already did the oil change.

Don't forget to check the air filter.

Ming · 08-27-2009, 11:54 AM

Quote:

Originally Posted by stubby

I think you covered it all, as I think you already did the oil change.

Don't forget to check the air filter.

yep oil changed to full synthetic.
and Thanks for reminding me about the filter! Almost forgot!

08-25-2009, 11:07 PM	#1
Ming Senior Member Joined: May 2008 From: Boise Posts: 1,574 I Ride: a 2008 KLR705	anyone know how swap forks? So it seems pretty basic, but do any of you have any experience swapping forks? I'm going to be putting some 07 zx-6r forks on my 636 as soon as they arrive. My fork seals are toast, and bike will stay garaged until they get swapped. Anywho, so I know if I do it myself I'll need to borrow a front fork stand. Once I have the bike in the air do I just loosen the bolts on the top and bottom of the triple and drop em? then replace and tighten? Anyone have any ideas if they have a guide to line them up? Or how you can make sure that both forks are even and straight with the bike? Carl's quoted me $100 for the forks and $30 to swap rotors, but if this is easily something I can get done properly in my garage i'd rather do that. I just don't want to chance it and have my forks be all wack...

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08-25-2009, 11:13 PM	#2
Waldo Joined: Jun 2007 From: What does it matter? Posts: 1,828 I Ride: RVT1000R RC51 SP1/SP2	Are the 07 zx-6r forks and your 636 a direct swap? Not all forks are the same size or use the same axle, spacers and wheels. If they are a direct swap then it is very easy.

08-25-2009, 11:15 PM	#3
Hoard Senior Member Joined: Sep 2006 From: Meridian Posts: 1,164 I Ride: 2007 CBR1000RR	For my CBR you just have to take off the wheel/rotors ect. Then unbolt the 8 triple tree bolts. The forks drop right out. As far as a guide to line them up.. I just used a tape measure before and after. Measuring from the top of the fork to the upper triple tree.

08-25-2009, 11:20 PM	#5
Waldo Joined: Jun 2007 From: What does it matter? Posts: 1,828 I Ride: RVT1000R RC51 SP1/SP2	Pretty much Remove and Replace. Do you have pinch bolts on one of your forks holding the axle?

08-25-2009, 11:21 PM	#6
CBRF2Old Joined: Aug 2006 From: Boise Posts: 4,856 I Ride: 83 and 84 Honda Ascot's and 91 CBR600F2	The only thing I know about swapping forks is when I accidentally grab one of the short ones (salad?) from the drawer and then have to dig for one of the long ones (meat eater). It really is pretty simple if all the parts are the correct size for the triple clamps etc. The big thing would be alignment. Run a string from the back tire (on both sides and assuming that the back tire is aligned correctly) to a point in front of the bike and measure from the string to the front tire. Also measure from the ends of the handlebars to a midpoint on the back of the bike to make sure that the bars are aligned. Tighten the bolts and u r good to go. I have done this on the CBR (and found that something is seriously out of whack, i.e. at least two crashes.), but it is not hard to do. Let me know when you want to do it and I might be able to give you a hand with it.

08-25-2009, 11:24 PM	#7
Waldo Joined: Jun 2007 From: What does it matter? Posts: 1,828 I Ride: RVT1000R RC51 SP1/SP2	I can also give ya a hand

08-25-2009, 11:24 PM	#8
stubby Senior Member Joined: Mar 2008 From: A boring place without any tracks Posts: 4,860 I Ride: 08 GSXR1000 street 08 GSXR600 race bike 99 TZ125 Smoker 07 KTM 250xcw dirt xr50 pit bike 49cc Pocket bike	Check out Jason's write up on corporatesuspension.com it might help you out and it has a few pointers along the way. http://www.corporatesuspension.com/s...w-to/forks.php

08-26-2009, 08:22 AM	#10
Cider Senior Member Joined: May 2006 Posts: 2,349	Stubby posted a good article, but I'll stress it again--be careful to torque the pinch bolts correctly. If they are too tight, you can actually bind up the springs, or possibly even crack a triple. Also, before you torque the pinch bolts on the front axle, take the bike off the front stand and bounce the front forks a few times against the front brake. Finally, if you have clip-ons, test your steering lock-to-lock to make sure they won't hit the tank. If you do this while the engine is running and the revs change, the throttle cable is probably binding up.

08-26-2009, 10:51 AM	#11
stubby Senior Member Joined: Mar 2008 From: A boring place without any tracks Posts: 4,860 I Ride: 08 GSXR1000 street 08 GSXR600 race bike 99 TZ125 Smoker 07 KTM 250xcw dirt xr50 pit bike 49cc Pocket bike	Ming you can use the stem stand this weekend if you need it, although I don't know what pin your bike uses. If you could look on pitbulls website and see what pin you need, I will see if I have it. I had one that worked for Brandy's ZX6r but your bike might be different.

08-27-2009, 01:20 AM	#13
stubby Senior Member Joined: Mar 2008 From: A boring place without any tracks Posts: 4,860 I Ride: 08 GSXR1000 street 08 GSXR600 race bike 99 TZ125 Smoker 07 KTM 250xcw dirt xr50 pit bike 49cc Pocket bike	I think I have both #2 and #2T. I will double check. I don't know about bringing it to work tomorrow as Matt said he wanted to ride into work tomorrow. Could always make the 2mile journey home at lunch and pick it up though if he drives in.

08-27-2009, 10:32 AM	#15
Matt Senior Member Joined: Jun 2007 From: Boise, Idaho Posts: 1,895 I Ride: 2006 Ninja GSXR 636	Apparently the county has decided to keep me off of my motorcycle by chip sealing and taring every F-ING road there is out from my house off of Federal Way!! GRRRRRRRRRRRR! Anyway, No problem I can drag it home for ya I'm sure the roads will be a crapshoot for the next few days anyway. Stubbs: You comin in to work today or what?!? hehe Slacker

08-27-2009, 11:32 AM	#18
stubby Senior Member Joined: Mar 2008 From: A boring place without any tracks Posts: 4,860 I Ride: 08 GSXR1000 street 08 GSXR600 race bike 99 TZ125 Smoker 07 KTM 250xcw dirt xr50 pit bike 49cc Pocket bike	I will grab the stand at lunch so your secretary Matt can deliver it for you. Would you like any coffee or sandwiches when he comes home? Did you still need to borrow the mity-vac for your brakes?

08-27-2009, 11:39 AM	#20
stubby Senior Member Joined: Mar 2008 From: A boring place without any tracks Posts: 4,860 I Ride: 08 GSXR1000 street 08 GSXR600 race bike 99 TZ125 Smoker 07 KTM 250xcw dirt xr50 pit bike 49cc Pocket bike	I think you covered it all, as I think you already did the oil change. Don't forget to check the air filter.