See also: GSXR750 Forks /Frontend install

SV1000 2002 GSXR Front End Conversion by JeffSV May 2005

The following is a list of tools required, and GSXR parts needed to complete the GSXR front end swap. I really can't do up a step by step with pictures as it's been done for a little while now.

SPECIAL TOOLS REQUIRED:
24MM Axle Tool (to remove front wheel)
32MM Socket (to remove top triple tree nut from SV clamp)
34MM Socket (to install top nut on GSXR clamp)
Suzuki Spanner Socket (This one I borrowed from a dealer as it was a one time use for me..needed to remove the triple clamp from the frame, and is a speciality tool.)
T40 Security Torx Bit (to remove and re-install ignition)
Good torque wrench.

RE-USEABLE SV PARTS:
Front tyre & rim
Front Axle
Front Brake Callipers
Front Brake Lines
All Left Side hand controls
All Right Side hand controls
Steering stem bearing both upper & lower

2002 GSXR PARTS REQUIRED
Upper & Lower Triple Clamps
Left & Right Fork's (Complete)
GSXR Front Fender
GSXR Left & Right Clip-On's
GSXR 320MM brake rotors

Above is a minimal list of what it will take for a basic swap....Some nice upgrades while your at it would be GSXR 320MM rotors, and 6-Pot calipers.

When doing this swap you will not be able to use either the stock SV steering damper, or the GSXR steering damper. Right now I'm running no damper and have 1000 trouble free miles, but the steering is a little light.

Alright here comes the short how-to version...if your not pretty handy with a wrench & a bike you may really consider finding someone who is to give you a hand.

1) Remove SV front fairing, fairing bracket& speedometer ( I think this is already covered on andy's site)
2) Remove SV front fender, brake calipers, and loosen wheel. If you are re-using the SV callipers and not switching to the 6-pot GSXR leave the brake lines hooked up but DO NOT HANG THE CALIPERS BY THE RUBBER HOSES. This can ruin your lines and cause you lots of greif later.
3) Raise the front of the bike off the ground...just till the tire clears. ( I used a strap under the front header pipe and lifted it from the ceiling with a cargo strap.
4) Remove tire & axle & set aside.
5) Using the T40 security torx bit remove the ignition assembly
6) Remove stock SV upper triple clamp using the 32MM socket, and left & right clip-on's. Remove forward controls from clip on's.
7) Remove stock steering damper.
8) Using the Suzuki speciality spanner socket remove the top nut (lock nut) holding the lower tripple clamp to the frame, then remove the actual nut that holds the lower triple clamp on. Now your whole front end should drop right out of the frame with the forks still attached to the lower clamp.

OK so now you've got the bike stripped as far as need be to begin installing the GSXR front end.

Part 2 2002 GSXR front end swap...the re-assembly

Alright lets put it back together.....I found that the best/easiest way to do this was to fit it all loose at first and the torque/tighten when done.

1) Insert new GSXR fork tubes into you GSXR lower triple clamp..don't worry about lining anything up yet, that's what our axle is for. Lightly clamp the forks in to the lower for now ( just so they wont fall out as you pick the assembly up.
2) Generously grease the upper & lower bearings (clean first if there filthy, replace if there worn)
3) With lower bearing in place insert forks & tripple up thru the frame.
4)Install the upper bearing and race-way, and thread on the top nut to hold it in place.
5) Temporarily install the axel thru the forks to align the bottoms.
6) Torque the steering stem nut with the Suzuki specialty spanner to 32.5 FtLbs., Install and torque the steering stem lock nut to 58 FtLbs.
7) Install left and right controls on to new GSXR clip On's and slide them over the fork tubes.
8) Install upper triple clamp over the clip on's and fork tubes. Install and tighten the top star nut from the GSXR clamp with the 34MM socket and torque to 65 FtLbs.
9) Move the GSXR fork tubes up/down until both tubes are at the same height & clamped just below the fork cap. This is max height that you can get out of the GSXR forks and puts the steering geometry as close to stock as possible. ( well not stock but real close to what people are doing raising there stock tubes in the triples anyway.) Tighten the upper and lower triple clamps around the fork tubes snugly but don't torque 'em yet.
10) Using the locator pins on you GSXR clip on's correctly position the clip on's and tighten to 16.5 FtLbs.
11) Re-install your ignition assembly using the T40 security torx bit.
12) Remove the axle you put in place temp. and install your front rim/tire with the new 320MM rotors mounted. And re-insert the axle to hand tight.
13) Torque upper and lower tripple clamps around the forks to 16.5 FtLbs.
14) Lower the bike back down to the ground, and torque your front axle to 72.5 FtLbs, and fork pinch bolts to 16.5 FtLbs.
15) Mount up your calipers(19 FtLbs), and new front fender, and your ready to rip

This is what I did not saying it's the only way or the best way but it worked for me, and to date from the swap I have 1000 miles on the bike with no problems to report. If you are one to death grip the bars don't even ride it without an aftermarket Scotts or GPR type damper.

Happy Riding, Jeff

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