Fork conversion using All Balls bearings

I'm looking for someone who has done a swap using a 77 kz650c (or similar) and a 06-12 Gsxr600 /750 front end.

I purchased the All Balls conversion kit assuming I would simply slide on the bearings a and drop the front end on the frames not the case.

Do these things need to be pressed on and do the races and spacers need to be used? Essentially I need a step my step, I have already thrown tools and I'm into my second full glass of scotch.

Help please

First at all you need your z650 stem fitted in the lower fork triple and have to use All Balls bearings for a z650
I add a how to fork swap and read this first before you do any cut or go the wrong way.

Don´t drink and drive or work drunken on your bike. Take a deep breath and get some sleep.
Ask here for more help if you want to know something.

Na den mal Prost, Cam pay, Chin Chin, Let it flow

Scirocco,
I am pretty sure all the AllBalls conversions allow the use of the existing stem, hence the term conversion.

The lower bearing is pressed onto the stem, and the bearing races are pressed into the steering neck. They can be a bear to remove.

I should have been more specific, the swap through All Balls doesn't require you to swap the stem. You can essentially put the new model stuff directly on the old frame with the use of the bearings.

I have chilled a bit, used the Internet and realized that the bearings need to be pressed on and I believe the original gsxr lower races need to be removed.

Thanks.


Ps- still drinking scotch and not driving any time soon

OK, i have checked this with the AllBalls conversions kit. I did´t know that special kits exist to adjust ID and OD to fit
plug and play the steering stem and the steering neck together. What about the length of the steering stem and the threat
to adjust the bearings play and the upper fork triple?.

Ya it's not exactly plug and play and I understood that going in. Thankfully the Internet is a valuable resource. I would still like to find someone who has actually done this to guide me along.

Thanks

To remove the bearing races from the lower stem i grind the races with a angle grinder on one position flat to weaken the races..Don´t grind to deep so you don´t grind into the stem or fork triple. Do it in small steps with a steady hand. If 0,50 - 1,00 mm thickness of the races is left heat up the races with a hand torch until it get blue colored. Mostly the races will cracked off. If not a little hit with a hammer and a chisel on it will do the rest. Now you can easily pull the races.
ALWAYS WEAR SAFETY GLASSES to protect your eyes (splitter fragments of the bearing races)

In some rare cases, dependent of the manufacturing tolerances, you need only head up the the races on the fork stem
and cool down the fork stem with water through the inner bore.
The stem OD will shrink and the races ID will expand enough to get it slide off easily.

Thanks man, I will give that a shot

So I got it all sorted out.
My particular application was mating a 2007 GSXR 600 front end to a 1977 Kawasaki KZ650C
I used the All Balls Racing conversion kit. I was able to remove the races from the GSXR600 triple tree fairly easily thanks to some good tutorials on the interweb. This was a good tutorial for the home DIY guy

I was fortunate to find that my bottom race on the kz650 frame was recently replaced and showed no signs of wear so I didn't have to smash it or cut it out.

When installing the new bearings on the triple I flipped the old bearing upside-down and used a ball pein hammer and a punch to slowly tap it down. Be sure to pack your bearings with grease prior to doing this. It's helpful to grease the hole stem so that in the event that you mis-hit with the hammer it will slide and not mare the stem.

Order of assembly for my application :
On the triple stem I went with this set up
1 - copper gasket with grease seal
2 - All Balls lower inside bearing
Put the triple tree up through the frame
3 - hammered in the upper outer frame race
4 - All Balls inner bearing (packed with grease)
5 - 3mm spacer (came with All Balls kit)
6 - original top cover
7 - GSXR threaded locker nut which allows you to adjust the tension
8 - 1 mm or so spacer
9 - GSXR top triple tree
10 - GSXR top nut
Be sure to pack all you bearings prior to install and grease the races.

That's about it for that install

If anyone sees any place where I've messed up please let me know.

Mike

.....and at the end everything will be fine. I would say, well done!!! Looking good and your frustration is gone.
Keep on posting your progress here and don´t be shy to ask, Nobody is or will be perfect.
Everyone here need some advise from time to time, me to.

Yes KZRider is a great resource.

Next I have to figure out how to do the timing on an existing Martek electronic ignition.

Any one have experience with a Martek440 by Martek Products Inc ?

If not I'm buying a Dyna S.

Thanks
Mike