Z1000 Fork Upgrade Complete

Bringing this back from the dead....

I am doing the same fork conversion now and I am surprised how cheap it is. 2004 model ZX6 forks, axle, and calipers for $320 from Fleabay! I sourced the bolts from Nepean Boltmaster. In stainless allen head they cost something like $14 total. All arrived with no bent or damaged parts.

nice stuff matt, that makes 3 so far

Slight error there. Boltmaster gave me 1.5mm thread instead of 1.25mm. When I returned them they said they dont do stainless in fine thread, so I grabbed black high tensile instead.

It should be around a week or so before the last of the bits... the back-ordered wheel spacers..... are in my hand.

Job done! Feels great, very highly recommended for everyone to do this. All up took maybe 2 hours from beginning to end.

Did you upgrade the springs and re-valve? Looks fantastic

I'd suggest wacking a cable tie around the lower fork to see how much travel you are using

I am using a fair bit of the travel, I am definitely no lightweight! Been using the cable tie check for well over 20 years. All standard for now but I have been contemplating some 1.05 springs in the near future. The dampening seems fine to me so far with the standard ZX6 settings and I think it will stay that way unless the stiffer springs show up a rebound deficiency. It is never going to a track, just purely a road bike so I dont mind it staying on the slightly softer side of what others consider perfect. Interestingly the firmer front end has made the rear feel like it needs a few clicks more rebound, but that is easy to do. I use the ZX6 rear shock too, also a bolt on.

I have to honestly say that anyone with a Zed that is considering some fork work should do this conversion. It costs bugger all, and if you get all the components ready it is a very easy job that anyone can do. We ended up making wheel and caliper spacers rather than buying off the shelf. Actually I have ordered the genuine wheel spacers but they did not arrive so we just made some to suit the OEM Zed spacers. For those interested, OD=40mm ID=25mm Width=2.5mm and you need two of them. The caliper spacers were 10mm thick with a 10mm ID. Cant remember the OD but I can measure it if anyone needs the info. Other than that it all bolts on. I used the 03-04 ZX636 forks and calipers but looking back I should have used the 05 model because I want the newer look front guard. Got these cheap so no real complaints.

I had to do the springs in my 08 conversion. They bottomed out instantly. 1kg springs spot on.

Did the swap to 1kg springs today and instantly feels better. It doesnt blow through the travel so readily and has allowed me to back off compression dampening a couple of clicks to make it feel less harsh. The springs were also 10mm longer which now brings my preload back into range.

BTW, if anyone is contemplating the conversion I have the wheel spacers available. The ones that we fabricated. The OEM spacers arrived a while ago and the fabricated spacers are now unused.

Last edited by Mattjin on Thu Nov 03, 2011 6:51 pm, edited 1 time in total.

Nice one welcome to the World of a better handling Zed

I stuck a 55 series profile rear tyre on last time I got new boots - wow, doesnt that sharpen up the steering

I did the same around a month ago, now running a 190/55. Not to mention new steering head bearings.

I stuck a 55 series profile rear tyre on last time I got new boots - wow, doesnt that sharpen up the steering

What profile did you have on before the 55?

I stuck a 55 series profile rear tyre on last time I got new boots - wow, doesnt that sharpen up the steering

What profile did you have on before the 55?

The stock 190/50 17, the 190/55 supposedly has more meat on the road when leaned over But also speeds up the steering somewhat

Might try that next rear,

Thanks

Did you upgrade the springs and re-valve? Looks fantastic

I'd suggest wacking a cable tie around the lower fork to see how much travel you are using

Tell me gents, what sort of travel should the shocks have?

Mine on my commute (no real "hard" braking) i had 70mm of travel.

Fork upgrade done by previous owner.