Installing a GSXR Front End on a Harley Sportster Motorcycle

An Overview of Putting a GSXR Front End on a Sportster

For many Harley-Davidson Sportster owners, improving handling and adding a more aggressive look are top priorities. One popular modification is swapping out the stock Sportster front end for an inverted fork front end from a Suzuki GSX-R sportbike model. This swap offers better ground clearance, braking, adjustability, and a more modern, sportbike aesthetic.

Benefits of the GSXR Front End Conversion

There are several key benefits to installing a GSX-R front end on a Sportster:

• Improved ground clearance - The inverted forks raise the front end compared to the stock setup, allowing for tighter cornering angles before scraping parts.
• Better braking performance - modern GSX-R brakes have stronger calipers and can utilize larger brake rotors.
• Fully adjustable suspension - inverted forks allow external adjustments to compression and rebound damping.
• Lower weight - GSX-R forks are lighter than heavy Harley fork assemblies.
• Sportbike look - the modern superbike-styled front end matches the Sportster's aggressive styling.

Considerations Before Starting the Swap

While this conversion offers some great benefits, there are also a few important considerations to factor in before taking on this project:

• The swap requires cutting and welding to graft the GSX-R forks and wheel onto the Sportster frame and controls.
• You’ll need a way to adapt the new brake system and instruments to work with the Harley controls.
• It can be tricky fabricating tabs and brackets to mount the fairing and headlight.
• Inverted forks change the bike's handling, which takes some adjustment.

Sportster Front End Removal and Preparation

The first steps in grafting a GSX-R front end onto a Sportster are removing the stock fork assembly and triple tree and then prepping the frame's steering stem. Here is an overview of the process:

Disconnect and Remove Components

To start, you'll need to disconnect and remove the following:

• Front wheel and fender
• Brake calipers, brake lines, and rotors
• Handlebar controls and cables
• Headlight housing and fork covers
• Top and bottom triple trees
• Entire fork tube/shock assembly

Clean and Prepare the Steering Stem

With everything disconnected, use a die grinder to remove any remaining fork tube or stem material from the frame’s steering stem. Smooth and polish the stem’s surfaces to prep it for welding. A bare, clean steering stem helps align the new fork tube perfectly.

GSXR Fork and Wheel Installation and Fabrication

With the frame prepped, you can start grafting on the GSX-R inverted front end components. This involves cutting, welding, and fabricating mounting tabs and brackets to adapt the forks, wheel, and braking system.

Graft the GSXR Fork Tubes

Slide each fork tube up into the Sportster’s frame from the bottom and align them evenly with the center line of the frame’s steering stem. With the tubes held firmly in position, tack weld them in place. Verify alignment, then finish the welds around both tubes to fully secure them.

Install the GSXR Wheel and Brakes

The GSX-R front wheel won’t lineup evenly with the Sportster’s axle position, so fabricating a new axle mount is necessary. Mark and weld shock tabs near the lower Sportster frame cradles. Then weld a cross bracket and special axle sleeves to create a solid mounting point for the GSX-R wheel to bolt to. Adapt the GSXR’s brake system by fabricating caliper mounts and custom brake lines.

Craft New Mounting Points for Controls and Fairings

You’ll need to craft new brackets, tabs, and adapters to mount the handlebar risers, gauges, headlight housing, and front fender for the bike following the GSXR fork swap. Get creative with aluminum and steel parts and pieces salvaged from other builds to DIY your own mounting solutions.

Finishing Touches for an Amazing Custom Sportster

With the major fabrication finished you can now handle final flourishes like wiring, body panels, controls, and paint. Here are some ideas to take your GSXR-Sportster hybrid to the next level:

Adapt the Wiring and Controls

Splicing, extending, and adapting wiring lets you hook up the GSXR gauges and head/parking lights. This lets you eliminate the stock Sportster headlight for a sleek custom look. You can also adapt custom controls like clip-on or clubman bars and rear-set foot pegs.

Craft Custom Bodywork

The frame and front end have an ultra-modern superbike look already. You can mimic racing bodywork by hand-forming side fairings out of thin aluminum sheeting or glass-reinforced plastic. Then rivet them in place and mold them to flow flawlessly with the fuel tank and seat.

Personalized Paint and Graphics

After all the custom fabrication your GSXR-Sportster mashup deserves a one-of-a-kind paint job to match. Consider wild color-shift paints, metal flake coats, tribal graphics, or custom airbrush artwork to make it truly unique.

With these tricks for completing a GSX-R front end swap, you can build the custom Sportster of your dreams. The finished bike will have unmatched performance, modern style, and plenty of garage cred with the Iron 883 crowd.

FAQs

What GSXR models are best to swap Sportster front ends?

Many opt for front ends from GSXR-600 models from the mid to late 2000s. These offer inverted forks and strong, modern brakes while being easier to adapt than 1000cc or newer systems.

Do I need welding experience to install the GSXR front?

Yes, you'll need decent welding skills for grafting and fabricating fork, brake, and component mounts. Consider taking a welding course or having an experienced shop help if you’re new to welding.

How much does the GSXR swap cost in parts?

Expect to spend $500-$1,500 on parts between the forks, wheels, brakes, and various hardware and materials. You can often source used GSXR components to save money.

Will the handling feel very different after the swap?

Yes, the Sportster will handle more like a nimble sportbike. The inverted forks offer less dive in hard braking and better cornering clearance. It takes some adjustment if you’re used to stock Cruiser dynamics.