ZX10 wheel swap details.

[Expat]

Here is the details for the wheel swap for the Gen 1 Z1000 to ZX10R
I used wheels from a 2006 model.
General information.
The Z1000 uses a 25mm dia axle.
The ZX10R uses a 20mm dia axle.
The ZX10R rear hub is narrower than the Z1000. therefore, the ZX10R axle is too short.
There are 2 ways to make the wheels work:
1. Fit larger I.D. bearings into the ZX10R wheel to accomodate the Z1000 axle etc. I did not go this route and my only concern would be the load and speed of a smaller diameter ball bearing as each actual ball is going to be aprox 2.5mm smaller in diameter. The spacers need to be adjusted to make the hub offset correct.
2. Use a smaller diameter axle and associated spacers and caliper hanger etc. This is the route I took and the one I am describing here.

For the front, you can use a ZX10, ZX6 or Z750 wheel, I made custom spacers so they matched the rear but if you do the 636 fork conversion, stock spacers from the 636 work. The axle etc fits also so it is a straight forward bolt in.
The rear is more tricky, because the hub is narrower, the offset is different and custom spacers are required to keep the chain alignment correct. The dimensions are shown in the drawings below. In addition to the wheel spacers, you will need 2 additional sets of spacers as follows.
2 swinging arm spacers which will take up the difference in the diameters from the 20mm axle to the 25.5mm slot in the stock Z swinging arm. I made mine 20.25mm I.D x 25.00mm O/D x 15mm (the thickness of the swinging arm slot), I cannot remember for sure but think it is 15mm. I had to grind mine slightly on the O/D to fit exactly. The other set is for the offset of the rear caliper. These can be custom made or you can use nuts which allow clearance over the caliper bolt. I made mine 18mm O/D x 8.5mm I/D x 15mm long and they work fine but I suggest you double check your own dimension here!
I used a Z750 axle which had to be shortened by about 10mm and the split pin holes re-drilled. I had mine re-plated but I guess some Silver paint will do! I then used 2 of the L.H side axle blocks from the ZX10R (one on each side) these are the thicker ones without the cut out for the axle head, I did this because the Z750 axle does not have the flats to stop it spinning when being tightened. If you use an axle with flats, it will need to shortened more but this means you will need to extend the thread which involves a special die nut, I am not sure of the actual thread size.
I have also attached dimensions for the footpeg pins which I replaced in Stainless for asthetic appearances.
I will post photos of the actual spacers in the next day or two.
If anyone has any specific questions, I will be pleased to try and help.
If you print off the following drawings and ask a local machine shop, they should be able to make them for you, like anything these days, the material is probably less than $20 but it will take someone probably 2 to 3 hours to actually make them all.

[Jason 306]

Good write up, I like it when people do this stuff. This may get a sticky. I like the ZX10 wheels, but they look like they would be much harder to clean than my stock Z wheels . But I like the stockers looks just as much as the zixxers

[Expat]

Originally Posted by Jason 306

Good write up, I like it when people do this stuff. This may get a sticky. I like the ZX10 wheels, but they look like they would be much harder to clean than my stock Z wheels . But I like the stockers looks just as much as the zixxers

I clearcoated mine about 6 times and left the lips polished, if they were a brighter color they would be more difficult to clean for sure, I usually use a biodegradable degreaser in a spray bottle, hose it off and then use furniture polish to shine them up. The polish leaves a slight film on the surface making future cleaning slightly easier! I think the appearance is worth the extra cleaning!!

[Jason 306]

Yeah, they look great! It almost makes the bike look like a European Z750 in a way (they have similiar rims don't they?).

Question: Do all the 07 ZX6's have silver forks? Do they differ from 05/06 636 forks? I really like the silver better than the gold, and the black at the bottom with black calipers looks killer!

[Expat]

Originally Posted by Jason 306

Yeah, they look great! It almost makes the bike look like a European Z750 in a way (they have similiar rims don't they?).

Question: Do all the 07 ZX6's have silver forks? Do they differ from 05/06 636 forks? I really like the silver better than the gold, and the black at the bottom with black calipers looks killer!

You need the limited edition one, the bike was Silver with Red flames. They also did Gold and I think that was the most common color. I am not sure what colors are available in 08.

[blufke]

Thanks a bunch for putting this up.

[extensive]

thanks for the info. how did you make the spacers? are you going to make them for sale?

[Expat]

Originally Posted by extensive

thanks for the info. how did you make the spacers? are you going to make them for sale?

The spacers were turned on a lathe. I do have a couple of spare sets of the actual wheel spacers but not the ones to shim the stock swinging arm or to offset the caliper. They are made in top grade stainless, the stuff they use on oil rigs etc!

[mezzo]

I need some advice
I have a2003 z1000 and i ve just got hold of a 2005 zx636 front end.
Ineed to know weather i can use my z1000 front wheel if so what axel and spacers do i use, do i use the zx636 axel and spacers to marry up with the forks? or do i need the zx636 front wheel + i want to use the zx636 calipers as well

and the big question will the 2005 front end fit my 2003 z1000

Mezzo

[Expat]

Originally Posted by mezzo

I need some advice
I have a2003 z1000 and i ve just got hold of a 2005 zx636 front end.
Ineed to know weather i can use my z1000 front wheel if so what axel and spacers do i use, do i use the zx636 axel and spacers to marry up with the forks? or do i need the zx636 front wheel + i want to use the zx636 calipers as well

and the big question will the 2005 front end fit my 2003 z1000

Mezzo

The front end will fit.
Regarding using the Z1000 wheel, see the thread for the 636 swap, it tells you which wheel spacers you need to use to make it fit.
good luck!!

[groovyone]

Making this one a sticky. Great writeup.

[Expat]

Originally Posted by groovyone

Making this one a sticky. Great writeup.

Why thank you. I will buy you a pint next time I am in Houston!!

[mezzo]

Thanks for your advice. im getting the front end this week,so im confident now

Many Thanks

Mezzo

[Expat]

Below is a photo showing the rotor side spacer and also the ones I used to offset the caliper. You cannot see the one used to shim the swinging arm down from 25mm to 20mm as it is located in the slot.

[RS117]

Great write up!!