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Sunday, July 31, 2011

Kawasaki ER6n-R ZX10R Front End Mod Part 1 - Fork Selection

Kawasaki ER6n a truly all round naked motorcycle which has tremendous potential. However built as an entry level budget motorcycle, it has numerous weak areas which can be improved with a few modifications. One of the weak spots is the front suspension which is built on an old school 41mm hydraulic telescopic fork. The telescopic fork is very basic without any pre load or damping adjustments options.
Improving the front end of the Er6 has been the challenge for many Er6n/f owners world wide and searching the Internet will easily uncover many adventurous individuals posting their modding efforts which is commonly revolving around utilizing the fork from the ZX6R or the 636.
I have choose to follow a path less ventured by using the front end parts from a few of the Er6n cousins which is the ZX10R.
My rational for this choice was made after extensive research from the Internet and discussion with the local track gurus. Decision was made after the following criteria were considered:
  • Mod options needs to be cost effective with minimum change to the components chosen.
  • Stock standard ZX6R / 636 forks were too soft and track going owners usually opted for stiffer springs soon after buying the sports bike.
  • Stock standard ZX6R / 636 forks (Kayaba) with a upper outer diameter (OD) of 50mm and a lower OD of 52mm and a length of 774.7mm is slightly longer then the base Er6 fork and will protrude too long above the upper triple when installed. This setup is fine if you are going with the Race clip-on type of handle bar (for the cafe racer look) but I however am looking to maintain the original stance of the Er6 with the Renthal type of handlebar.
  • The ZX10R fork which has a top triple OD of 50mm & lower OD of 54mm would be stiffer and looks beefier then the slimmer and longer ZX6R fork. There is a slight weight difference between the 2 forks (ZX10R weights a few grams heavier) but I did not feel the difference when riding. The slight weight difference would also act as a ballast to stabilize the vibration which the ER6n as a parallel twin is so notorious famous for.
  • The ZX6R fork is using a front wheel shaft that would need a 6005 sealed bearing with an internal diameter (ID) of 25mm 47mm(OD) would need extensive modification of the ER6n front wheel or a replacement with a complete ZX6R front wheel ($$). The ER6n wheel uses a 6004 bearing which has a ID of 20mm and an OD of 42mm similar to the specification of the ZX10R wheel from 2004-2005. This would mean that the fork from 2004-05 ZX10 you would just bolt on to a ER6n wheel without any modification.

16 comments:

  1. Great work your front end mod!!!

    I keep track of your blog for more ER-6 mods.

    V'sssssssssssss

    ReplyDelete
  2. Replies
    1. Hi there, thank you for sharing this information. Now I just might ha e a clear direction on which fork to purchase. Regards - Instagram @red_kawa_progress

      Delete
  3. Great blog here, more detail on front end swapping process would be perfect :D

    A question, what axle bolt did you use? ZX10 or ER6 one?

    Gotta try to gathering all the necessary parts first, it's difficult to get a decent condition sport forks here in bangkok. But the lower triple of versys will be easy and cheap :)

    ReplyDelete
  4. Used the ZX10R Axle & spacer, just need to ream out the Versys lower triple to fit the 54mm ZX10R fork. ZX10R fork is easy to get on ebay US.

    ReplyDelete
  5. Hi, May i know what is the headlight used ?

    Also about the Versys swingarm...

    If i buy a Versys swingarm, is it a direct fit ?

    Can I use the stock rear shocks ?

    Last but not least... Can i just use ER6 front axle ?

    Thanks a lot for ur time...

    Thanks...

    ReplyDelete
  6. its a yaamaha MT03 headlight
    yes direct fit for versys swingarm
    yes u can use the stock shocck
    No u need the ZX10 axle
    hope it helps

    ReplyDelete
  7. Hello mate. This is awesome. Glad i got told aboit your blog. I am in the process of customising my er6n now. With the versys swing arm. You can get a bigger tyre but have been told it will make the chain be out of line with the front sproket. Do you know a way of countering this so a bigger back tyre csn be put on?
    Cheers oli

    ReplyDelete
  8. Think the 5.5 is the biggest a Versys Swingarm can take without any alteration to the front sprocket position. I have a section covering this mod as well. The space between the chain and the edge of the tire is wee so small after putting in the ZX6 5.5 rims and 180 tire. No problems after more then a year riding the combination configuration.

    ReplyDelete
  9. Hi, Great mods.

    Can i just check what year your versy's Swing arm is? or does it matter - in terms of a direct fit?

    Cheers.

    ReplyDelete
  10. All years will fit, mine is a new unit from a 2012 Versys

    ReplyDelete
  11. Great job mate.
    I have a question regarding the selection of the fork. Why the 2004 model ZX10 and not say, the 2010 ZX10? Are they not the same size OD's?

    ReplyDelete
    Replies
    1. The 2004 model ZX10 and the 2010 ZX10 forks do not have the same OD for the wheel shaft clamp area.

      Delete
  12. Hi there. May I ask where you found the dimensions of the different diameters? I searched Kawasaki parts manuals but they do not specify the outside diameters. And also the lengths of the steering stems, how would one know which ones would fit?

    ReplyDelete
  13. Thats the trick, the manual will not specify the OD, thats why you have to look at the bearings. Do a search on the bearing model and walla...you will get the OD of the bearing which = the diameter of the shaft. On the steering stem, its a trial and error method. I bought a few Triple trees and tried them on but doing extensive research on the Internet websites and forums helps.

    ReplyDelete
  14. I got a question, i got a versys 650 from 2006,can i just slip in the zx10 forks? Or is there something that fits directly. I want better brakes and suspension.
    Sorry that my english is bad, km from Germany.

    ReplyDelete

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