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Discussion Starter #1 (Edited)
Hi all, I thought id document my journey so as to help others with similar aspirations to mine.

Firstly about myself - Im not sensible. I could easily buy a better bike and be done with it but this is not about me having a better bike its about building something as an expression of me and my personality. A little unconventional or eccentric if you will. I used to work on cars but now that im older and my back isn't as solid working on bikes seems like a way for me to tinker with stuff without the pain of lifting and bending too much.

The bike is called El Diablo Negro (the black devil) - My Venezuelan mate named it because its black and its really fricken loud.
Im located in Sydney Australia and whilst other people around the world use the warmer months to ride and work on bikes in winter, we have the advantage of being able to ride all year round. Though I don't do that I did go for a 1000mile touring ride right after I got my bike in extremely cold weather. just for the hell of it.

I bought the bike in 2011 when it was about a year old. Its a 2010 ER6NL ABS. Whats an ER6NL? Basically an er6 with a throttle stop and a lower rev limiter for learners.
both of those limiters are easily removed if you want to.

I bought it used with a two brothers pipe and I like it because its loud. From some angles the bike looks pretty good and its fast enough for me. From some angles though it doesn't look great and the suspension doesn't inspire confidence and so im seeking to remedy these things as part of my "journey"
Since buying the bike I've added short levers and some bar end mirrors which have helped the appearence of the bike a little but im still not satisfied and I've decided that rather than just trade up I want to keep this bike.

So what do I plan to do ?
Upgrade front forks
Upgrade front brakes
Upgrade headlight
Upgrade rear shock
Upgrade headlight and gauge
Upgrade rear wheel
Upgrade rear sets

For the forks
Ive purchased a set from a z1000sx along with the axle, brake callipers, spacers lower triple and front mudguard
Ive got a 2006 upper triple
In theory with the exception of the handlebars (which I think will need risers) it should all bolt up including the brakes(both my bike and the donor have ABS)

For the headlight I've found a nice 5 1/4 inch LED headlight on eBay with angel eye ring around the outside which I hope looks good but well see

For the rear shock I have 2012 R1 shock which ill get revolved and an appropriate spring put in
These have much more adjustability and are the right length with some mods

For the gauge
Motogadget mini and idiot lights eventually but for the moment the standard gauge with the cowl removed should do

Rear wheel
Chemco make a 6 inch wheel and I've found a distributor in Indonesia which might be able to help me.
If not a 636 rear with a kit from blue ridge or TWF racing will get it done
Ill also need a tyre and ill do both ends when im at that point

Rear sets
Ill be getting a set of RSV racing ones from Thailand. Thanks to Tremonte for putting me on to them and also for putting some great vids online.
https://www.rsvracing.com/en/

So some photos first
 

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Discussion Starter #2
2006 top triple/yoke

The 2006 top triple with the handlebar bracket was selected because it fits 50mm fork legs, bolts up to the standard er6 stem, has handlebar risers, and the ignition lock ends up in the same place as the er6 which apparently means I don't have to forego this functionality

2006 z1toptriple.JPG
 

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Discussion Starter #3 (Edited)
2012 z1000sx forks

These are the 2012 z1000sx forks
Note that the fork legs stick out the top of the triple on the z. This allows for clip ons but I want to use a flat bar.
I haven't received these from the seller yet but will need to measure the fork length, stem length etc and see how it all shakes out...risky, but hey wheres the fun in not taking any risks right ? I checked and the stem and wheel bearings are the same for an er6 and so I can use my front wheel (and my er6 stem if I need to)
The steering stops appear to be in the same location as stock er6 so another win.

IMG_0719.PNG
 

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Discussion Starter #5
If theres anyone who might be in need of any of the stock parts as I go and you're in Sydney - let me know.
Headlight
Forks
Front brakes
Rearsets
Rear shock
Rear wheel
 

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Im not sensible. I could easily buy a better bike and be done witht
This is a pretty accurate comment. I get what you are doing, but you will still have the standard, very ordinary handling frame. I believe that a few previous members used the 636 front end for the conversion. Shouldn't be hard to search the threads here.

Although you have bought the forks, here is a link to the conversion in another forum: https://www.kawiforums.com/ninja-650r-er6/101215-636-fork-swap.html

Anyway - good for you for having a hobby that keeps you off the streets. :righton:
 

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Thanks for reading and for the link. I’m aware of the various threads where others have done fork swaps .
No probs mate. Each to his own when it comes to project bikes. There's a thread here by a guy who turned his into a street-fighter. - might be worth a look for some ideas. Good luck with that.
 

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Are you just trying to be an smartarse now? I was riding and working on motorcycles before you were an unholy stain in your illegitimate Daddy's underwear. ..as were many members here. Your profile says you have been here one month and already you think you are somebody who can try to put down other members - reality check: you are not. Newbie - read it - learn what it means. SMFH...just another tosser....go away...find another forum.
 

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Discussion Starter #11 (Edited)
Are you just trying to be an smartarse now? I was riding and working on motorcycles before you were an unholy stain in your illegitimate Daddy's underwear. ..as were many members here. Your profile says you have been here one month and already you think you are somebody who can try to put down other members - reality check: you are not. Newbie - read it - learn what it means. SMFH...just another tosser....go away...find another forum.
Lol Wut?
 

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Discussion Starter #12
It seems you might have a negative perception of the world. All i did was offer up the threads id used as a reference and asked for any others that anybody might think would help. If that’s being an arsehole Im happy to be called one.
 

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Hi Oz, easy on the noob. I'm still a noob myself, although I'm a year older than you. Another guy here is 72yo, and is still a noob. All noobs are welcome, yes? What's important is to learn, and share what we learn. Ride safe! :)
 

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Discussion Starter #14
What's important is to learn, and share what we learn. Ride safe! :)
Yep, thats essentially what Im aiming to do here. Heaps of people have used Versys lower and 636 uppers with an assortment of forks including ZX10r, 636 and even R6. I couldn't find anyone in all of the forums that had used z1000 forks and indeed the z1sx may even be rarer.
 

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Discussion Starter #15
So my forks haven't arrived yet, so I reached out to the z1000sx forum to see if anyone had measured their forks so I could compare . Nice bloke by the name of Burty replied a short time later
Heres what he had to say.....


F Front brake caliper mounts are 108 mm apart

Front Fork tube (Diameter 50 mm at the top yoke)
Total tube length 520 mm
Top of top yoke to top of tube: 29 mm (i.e. the bit above the top yoke that has the clip-on clamped to it) (Although the book says this should be 27.9 mm)
Top of top yoke to top of bottom yoke: 239 mm
Top yoke thickness at the clamp: 23 mm
Bottom yoke thickness at the clamp: 41 mm

Distance from bottom of fork tube to the centre of the front axle: 235 mm (with the bike unweighted on the sidestand)

I would swear that the forks and brake caliper mounts are the same on this bike as the 2011 bike but can't be certain of course.

Top of bottom yoke to top of the top bolt: 245 mm
Top bolt head depth including the washer: 10 mm
Bottom of top yoke (Effectively the top of the stem locknut) to top of top bolt: 32 mm
 

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Discussion Starter #16
Having issues getting the 6inch wheel out of the Indonesians. 1 shop says they have no stock. Another shop says that they have 1 but won't send it abroad. In the meantime if found an obscure uk versys forum post from 2009 that says that an 04-06 z750 wheel goes straight on. I can get one for $75... :) Guess I know what I'm doing this weekend then.
 

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Discussion Starter #17 (Edited)

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Hi Oz, easy on the noob. I'm still a noob myself, although I'm a year older than you. Another guy here is 72yo, and is still a noob. All noobs are welcome, yes? What's important is to learn, and share what we learn. Ride safe! :)
Hi Blue. Of course you are right...maybe the noob doesn't know how to express himself well. I'm wondering why he is here - there is an Aussie Ninja 650 forum.
 

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"wut'...hhhmmm. Won't even go there. But hey - good luck with the build. I certainly have no interest now, and judging by the replies you have received - neither do a lot of members....I guess that it's going to be a nice little esoteric journey for you. Have fun and keep sharing.
 
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