'04 to '05 front end conversion - Yamaha R6 Forum: YZF-R6 Forums
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post #1 of 9 (permalink) Old 11-04-2012, 07:58 PM Thread Starter
My R6 eats me.
Join Date: Aug 2012
Posts: 23
'04 to '05 front end conversion

Hello all,

I was encouraged to share my project with everyone, so here it is. No big deal, just swapping my 2004 R6 conventional forks and calipers for the better and beefier '05 inverted forks and radial mounted calipers.

The driving force for the swap was mainly wanting better brakes for the street. The conventional brakes were fine in most situations, but in others, I could definitely see some room for improvement.

The hardest part of the entire job was really just getting the brake lines squared away. I was under the impression that the SS lines I already had on the bike would have worked, but the right side line was just a couple inches too short. After ordering new Spiegler lines from STG, I had to use the '05 horn bracket assembly, but modify it to accept the aftermarket lines. And btw, I think the fitting adjustment tool Spiegler includes with the lines are junk. But the lines themselves are fine, IMO.

So here are some pics….



Almost Done:


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post #2 of 9 (permalink) Old 11-04-2012, 09:30 PM
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Location: Irvine
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Bike: R6/R1 Hybrid
Re: '04 to '05 front end conversion

Nice work buddy! Your steering damper works on the new setup?

R6/R1 hybrid
Zeus Armor crash cage, sub-cage, stunt stay, subframe brace, R1 rectifier mod. ATC steel subframe & ATC 12 bar. Runman big rotor HB setup with r6 monoblock calipers. Stunter-X res clamp hose kit. Dented gas tank with HT moto grip. Kleen air mod. GPR V1 steering damper. Brembo RCS 19. SS brake lines. BMC air filter. ATC adjustable clip ons. Brembo 16x18 HB. 05 R1 front forks. 06 FZ-6 rear rotor. NGK plugs. DCP radiator cage. LP gas cap. Secondary radiator fan switch setup. HT Moto Rear Seat. Leo Vince CBR 250 exhaust. Naarden shark fin. 14/54t 520 gearing. Intergrated rear turn signals. Engine Ice. Shaved wind screen.
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post #3 of 9 (permalink) Old 11-05-2012, 10:24 AM Thread Starter
My R6 eats me.
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Re: '04 to '05 front end conversion

Yea, thankfully was able to keep the Scott's with the '05 front.
Consequently, I have the '04 conventional front end available if anyone needs it. Let me know, good price for it.
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post #4 of 9 (permalink) Old 11-05-2012, 05:52 PM
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Re: '04 to '05 front end conversion

Did you change the rotors also?
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post #5 of 9 (permalink) Old 11-05-2012, 07:12 PM
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Re: '04 to '05 front end conversion

How much were you able to pick up the 05 front.end for? Did you have to.change out the tripples?
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post #6 of 9 (permalink) Old 11-06-2012, 04:27 AM
My R6 eats me.
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Re: '04 to '05 front end conversion

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post #7 of 9 (permalink) Old 11-06-2012, 10:49 AM Thread Starter
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Re: '04 to '05 front end conversion


Yea you have to swap the rotors when switching to the '05 front end with radial calipers. The '04 rotors are 290mm and the '05 rotors are 310mm.


I grabbed the forks, rotors, calipers, lower tripple and stem for about $400 or so. Had to buy an upper tripple tree and I bought clips ons for it as well. You do have to use different triples because the inverted forks are bigger (I think 50mm if I remember correctly, up from 41mm), so they '04 trips wouldn't fit the new forks.
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post #8 of 9 (permalink) Old 11-06-2012, 06:48 PM
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Join Date: Mar 2009
Location: Virginia
Posts: 827
Bike: 07 R6s
Re: '04 to '05 front end conversion

For anyone else that is wondering how to...

Parts needed:

Forks ('05 o r'06 & up) '05 are 8mm longer, '06-07 same height, '08 & up are 10mm longer
Front Fender ('05 or '06 & up) 05 is an R1 fender, 06 & up is the newer front fender
Clipons (from' 05) works the best
Upper & Lower Triple Trees (from '05) works the best
Brake rotors ('05 or '06 & up) the carrier looks different but same size
Brake Calipers and bolts ('05 & up) all the same, gold or silver
Brake Master Cylinder w/ brake lever (05 & up) also need the banjo bolt
Brake lines (05 & up)
Horn Bracket and plastic shield (from 05)
Front axle ('05 & up)
120/70/17 Front Tire instead of the 120/60/17

You can make the 06 & up triples work by either shimming the stem under the upper
triple tree or by pressing the stem out of the lower and swapping it. Clipons under the
triple tree interfere with the ram air tube covers. Like I said you can make the 06 & up
Trees and clipons work but the geometry is different in the trees and it will actually
shorten the wheelbase. I recomend the 2005 Triple trees but the forks don't matter as
much as long as you set the height right.

Modifications- PCV w/ Autotune, LCD, & Quick Shifter, GraveSport Slip-on, Slide Stops, K&N filter, Factory Pro +4 Ignition rotor, SuperFlare Velocity Stacks, AGG block off plates, Fren Tubo Type 4's, EBC HH Brake pads, 520 Driven Sprockets & EK ZZZ Chain, Penske 8987 shock, 07 USD Forks and Brakes in 05 Triples, ASV C5 Levers, Scotts Steering Damper, GYTR Carbon Chain Guard, GYTR Carbon Toe Guard, Canadian GYTR Frame Sliders, GYTR Carbon Tank Pad, BST Carbon Rear Fender, Competition Werks Fender Eliminator, UFO Integrated Tail Light, Metzler M5 D-Spec Tyres, Gilles Chain Adjusters & Lifters, Gilles Rear-sets, Powder Coated Passenger Rear-sets, GYTR Seat Cowl, SaddleMen Seat, Irate Customs Grill, Gregg's Flush Mount Signals, DDM 5K H.I.D.'s, Integrated Beltronics 985, and
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post #9 of 9 (permalink) Old 11-07-2012, 11:12 AM Thread Starter
My R6 eats me.
Join Date: Aug 2012
Posts: 23
Re: '04 to '05 front end conversion

Awesome, thanks Phrozen. Hopefully that will help some others out in the future. And fyi, I believe the 120/60 tire can be used without any problem.
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