It looks like just about everything has been ticked off the old shopping list. My forks arrived a couple of days ago and besides a bit of weeping from the seals (but no pitting within the travel.... Phew...) they're perfect
. That said I couldn't believe how much shorter they are than the 5JJ's! However said fork length shouldn't be a problem once they're fitted to the wheel (will be using the original FZS600 wheel), and I will be using bespoke under-yoke-clip-on’s to avoid any fouling against the tank, also meaning I should be able to use all of my current handlebar switchgears, throttle tubes, levers, etc. May opt for some larger bar ends pending how much vibration I get off the clip ons. Hopefully very little- this is only a FZS600 after all. Possibly heated grips also, we’ll see.
Having spent the last week milling over old microfiche I've come to the conclusion (and feel free to challenge me on this; I'm not 100%) that whilst any of the 2003-2010 mudguards will be compatible with the 5PW forks, any of the R1 yokes should be compatible to one extent or another. Sadly there is variation between 4XV/5JJ and 5PW mudguards, and without them in front of me I can't tell whether said variation is purely aesthetic or whether the position of the mounting bolts has actually changed. Fork diameter didn't change until much later, so it looks like the 4XV, 5JJ, 5VY and 4C8 yokes are all compatible with the 5PW forks- the only change being position of the pinch bolts for some reason; it looks like the more recent R1's move the pinch bolts closer to rider position, and exaggerate that funny contour on the top yokes that engineers just go mad for. For that reason, I'm looking for a top yoke as close to the year of my forks as possible. It goes without saying, ideally the same year
It may be that some of the more recent top yokes are thicker than the earlier models, so I'm intending to see a couple of local bike breakers to measure up these yokes and see for certain.
Also for anyone interested, I've been in touch with a few suspension specialists regarding the R1 fork springs, and the only one to give me a clear definitive answer is K-Tech. Apparently the original 8.5N fork springs installed in the '03 Yamaha R1 forks will be fine for the FZs600 conversion. My local Yamaha franchise dealer confirmed this. Evidently the 30-something-kg difference in wet weight is negligible, but I am taking this with a pinch of salt- race techs tending to fall on the stiffer side of the spring spectrum than what I'd typically want for road use.
So forks, spindle, spacers, speedo, steering stem, headstock bearings, adjuster and lock nut, front wheel, brakes, instruments, another complete Fazer lock set... all check. Besides the shroud for the steering stem/ top yoke, the top yoke itself, clip ons, bar ends and the front fender am I forgetting anything?
Also any opinions on changing brake lines, etc whilst the project is underway??