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Old July 25th, 2023, 09:40 AM   #1
Fred659
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08-10 zx-10r Fork on 250/300 (Stock Front Wheel)

Hi,

It looks like I can't keep from doing upgrades on the little bike. I want to share this one with you guys cause I'm pretty glad / proud f the result. I always wanted to put a "better" fork on the 250 and the previous mod (zx-10r cartridges) was good, but I wasn't fully satisfied. So last fall, I decided to try to fit 08-10 zx-10r tubes on the bike while keeping the stock front wheel.

The first good find was that the 13-16 Triumph Daytona 675r triple tree has 54mm/50mm clamps and are a bit narrower than the ZX one while having a smaller shaft. It allowed me to only change the lower bearing seat. I needed to fabricate a stopper as the nobs on the 675 triple tree are way off and I need to control the movement to avoid damaging my steering damper.

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I managed to keep the stock front axle (only had to file hex faces to allow it to enter the ZX axle bushing). I need a washer on each side (wheel bushings) to get the proper dimension I need.

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For the brakes, I went with the 06-07 Yamaha r6 Rotors and the 2016 Triumph Daytona 675 Nissin Monoblock caliper (and some Galfer pads). You only need to bore out the screw holes a bit and shim the rotor whit some m10 washers (goes around the shoulder part of the screw). I also had a ss braided brake hose left for the prior build. I treated myself with a Brembo 15 RCS Corsa Corta Master Cylinder (Same as my ZX, which is 17 RCS...) and TWM clutch lever. I didn't what to have the brake supports on the left fork so I put the grinder into it ( i didn't butcher it too much).

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As I went keyless, I decided to do a bracket for the SOLO 2 Lap Timer using the key barrel threaded holes.

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Last futzed with by Fred659; August 3rd, 2023 at 04:54 AM.
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Old July 25th, 2023, 09:44 AM   #2
Fred659
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And here's the final result. I hope it could help someone with his project.

Cheers.


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*****Little Update:*****

I had to modify the belly pan as the front tire was rubbing when braking.


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Last futzed with by Fred659; July 28th, 2023 at 09:55 AM.
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Old July 25th, 2023, 11:04 AM   #3
superkain
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holy cow, that's awesome! how does it ride, now that it's together?
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Old July 25th, 2023, 11:24 AM   #4
Fred659
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Quote:
Originally Posted by superkain View Post
holy cow, that's awesome! how does it ride, now that it's together?
just finished it today. I need to go to the track to be able to tell you how it goes.

The brakes feel awesome so far (street shake down).

Glad you like it.
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Old October 28th, 2023, 04:54 PM   #5
sharky nrk
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Wild man, good job.
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Old October 28th, 2023, 05:08 PM   #6
Fred659
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I did try the bike on the track (rain and dry) and the bike is way more planted than before.

I can lean on the front way harder and it's exactly what I was hoping for. I no longer have to balance the bike on the gas on corner entry.

I will put the 2nd softer spring cause the combined value of 0.925 (1.00 + 0.85) is a bit to firm. I had .90 on the modified stock fork and it was pretty good so I will try the .85kg setup next spring. If too soft, I will buy son used zx-14 springs that are .90kg/mm
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Old October 30th, 2023, 07:30 AM   #7
sharky nrk
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Did you happen to have those springs handy? Notice any issues running such different rate springs left and right? I have known people to run one step difference springs left and right to make a half step, but not that big of a gap.
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Old October 30th, 2023, 07:59 AM   #8
Fred659
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Quote:
Originally Posted by sharky nrk View Post
Did you happen to have those springs handy? Notice any issues running such different rate springs left and right? I have known people to run one step difference springs left and right to make a half step, but not that big of a gap.
No real problem to be honest. Forks are "rigid" assembly by definition (you don't want the wheel to twist when the fork travels). I'm sure it's best to have close matching springs, but if you look at mountain bike forks (ex: Fox) you have 1 spring / air chamber in one leg and hydraulics in the other.

I felt way more flex with the stock fork than the modified zx-10 one.

Tin foil hat moment: I would not be surprised if the "no big difference in rates" comment came from springs manufacturer or seller. I have no proof if either are true or false. I just have my experience (14 years on track and 10 in suspension setting). I never saw a problem, but I would really appreciate if someone have a definitive answer backed with data.

...and for the springs, I have a set of stock zx-10r 1.0, a set of 03 gsxr-1000 0.85. I can buy zx-14 0.90 on eBay. (you only have to enlarge the tapered end as I did with the gsxr ones

Last futzed with by Fred659; November 19th, 2023 at 07:40 AM.
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Old February 22nd, 2024, 03:03 PM   #9
njshore2002
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Hey Mate love what you have done with the engine swap and the fork change. I actually recently engine swapped my 250 to a 300 just like you did and now im looking to do the front fork. the fork im looking to use is a 1998 ZXR250 fork. now im not too worried about getting it to fit, its more the fact that i want 4 Pot calipers on the front and im wondering if you know of any models of bikes that have 4 pot calipers that will bolt straight onto a zxr250 fork and rotor

cheers in advance.
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Old February 23rd, 2024, 01:52 PM   #10
Fred659
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Quote:
Originally Posted by njshore2002 View Post
Hey Mate love what you have done with the engine swap and the fork change. I actually recently engine swapped my 250 to a 300 just like you did and now im looking to do the front fork. the fork im looking to use is a 1998 ZXR250 fork. now im not too worried about getting it to fit, its more the fact that i want 4 Pot calipers on the front and im wondering if you know of any models of bikes that have 4 pot calipers that will bolt straight onto a zxr250 fork and rotor

cheers in advance.
I personally don't know, but if you have one stock caliper on hand, you can measure the c/c dimension and try to match it from other caliper dimensions. I asked some eBay vendor to take some measurements when I was looking for a fork.

try a google search for: zxr 250 front calipers swap. you should be able to find something

I saw fz6 mentioned a lot.

it's a dark art the one of bike modification.

good luck.
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