grunt
Parking Attendant
Posts: 23
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posted September 22, 2006 03:41 PM
04/06 Front wheel swap
Can someone who knows a good fix please advise? I bent the front rim on my 06 and the rear got a little out of true in a little accident I had. Believing [and being told] the 04 and 06 wheels were interchangable I got hold of a nice used set of 04 wheels and the back went on no problem. The front looked identical except when I went to mount it the axle was too large for the bearings. Turns out the 06 uses identical front and rear bearings but the 04 doesnt. I could have the hub machined out to the proper size or maybe get an 04 axle and locate bushings to fit the larger openings in the fork. Dont want to lose these wheels as they look so good and the rear wheel was an easy fit. The front wheel castings appear identical - it seems Kawi wanted to cut down on their parts inventory and opened up the front hub just enough to match the bearing size with the rear wheel.
  
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GUNNER
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posted September 22, 2006 03:59 PM
 Edited By: GUNNER on 22 Sep 2006 17:04
Dude it's a simple bearing swap. The bearing have the same OD between years but the ID is smaller on the 04/05 models. Just put the 06 bearing in the 04 wheels and the inner spacer as well. The 04 uses a 6004 bearing up from and the 06 uses a 6005 bearing up front. THe 05 636 uses the 6005 as well and has a bigger axle than the 05 10R. I have both here and have changed the bearing in both.
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grunt
Parking Attendant
Posts: 23
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posted September 22, 2006 07:28 PM
Gunner, I wish it were that simple but I promise the OD on this 04' front wheel bearing is smaller than my 06' by at least 1/8th inch. The dealer that sold it to me said it came off an 04' ZX10 and marked it as such. Its got factory black paint on it and its identical to look at except there is obviously more aluminum around the bearing as you look at it in the hub. I pried out the outer seal [not the one in the bearing] and made sure I wasnt seeing things.
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GUNNER
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posted September 22, 2006 07:42 PM
Edited By: GUNNER on 22 Sep 2006 20:56
I STAND corrected!!!!!!! Sir you're screwed here! I checked the fish and found that the bearing sizes I Quoted were correct so I went to the tool box and pulled out the old set of bearing I had for both and MUCH to my surprise the 6005 was larger OD than the 6004. Looks like I need to brush up on what the bearing numbers mean myself. Sir I gave the wrong info to you and I'm sorry. Well, at least it was half wrong, but it was the bad half that I was wrong on.
At this point I would have tpo measure the wheels to see if in fact they can be opened up! It would be a dangerous situation to get that area too thin. Tread lightly here, and be careful if you do open them up. These wheels on the 10R are very thin to start with as you have already discovered.
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grunt
Parking Attendant
Posts: 23
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posted September 23, 2006 09:44 AM
Apology accepted! I'm little screwed for sure but I'll take it as a challenge.... I think a good machinist could convert the bearing seat to 06 dimensions just like Kawi did but if I can find an 04 axle it might be easier to fit a sleeve in the fork opening. How confident the machine shop is will help decide which route I go. Thanks
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GUNNER
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posted September 23, 2006 10:01 AM
Another option would be an 05 636 front wheel. Same exact bearings as you 06 10R. I'm a machinist and if the two wheels measure out and there's the same amount of material left in the 04 front wheel after machining the bore out than I see NO problem with doing that, BUT!!!!! If it get's any thinner than the 06 wheel I wouldn't. Kawasaki may have had the 06 wheel cast a little different for the bigger bearing..... BE CAREFUL!!!! Saving a buck won't be worth your life 
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grunt
Parking Attendant
Posts: 23
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posted September 23, 2006 01:33 PM
Good advice- thanks dude. I just survived getting flung into a guardrail at about 50 miles per with only cuts and bruises so I think I'll play it safe for a while.
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GUNNER
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posted September 23, 2006 01:38 PM
WTF! Hell dude when did that happen??
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GUNNER
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posted September 23, 2006 01:39 PM
Was that your pictures over at .NET?? with the 06 sitting beside the rail with the nose ripped off?
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1badzx12r
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posted September 23, 2006 02:13 PM
grunt to your surpise.. i take my rim into a auto parts store or bearing shop or machine shop and get customs from them to match up... i've done this in the past..i just don't know what kind of parts store are in your part of the world
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http://www.youtube.com/watch?v=S06nIz4scvI
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grunt
Parking Attendant
Posts: 23
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posted September 23, 2006 02:52 PM
I dont know if anyone took a pic at the scene with a camera phone and posted it...I had it upright before my buds came back up the hill. Its a yellow 06 and the plastic was all tore off and hanging. This was two weekends ago in the Black Range, southwestern NM. Every couple of months someone gets a medevac ride out in a copter. I was an idiot because the place is an awesome ride if you pace yourself but these were home boys wearing race rubber and I should have let them go. I'd see a little bit of straight and it was too tempting to gain some ground there. I let it pick up too much speed and by the time I saw how tight the turn was it was too late to slow down. If I hadnt low sided at the last second the guardrail wouldnt have stopped my sorry ass from going over a cliff. Frame, forks and tank are good. I sprained my hand, bled a little and was really sore all over for about a week. Bottom line is I was lucky as shit not to wind up in wheelchair. Be careful my friends- when it happens, it happens quick.
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1badzx12r
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posted September 23, 2006 02:59 PM
i've done 152 a bunch know the road well...not a road for rookies... not bashing any skills... i just know a person better have their shit together on 152
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http://www.youtube.com/watch?v=S06nIz4scvI
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GUNNER
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posted September 23, 2006 03:30 PM
Edited By: GUNNER on 23 Sep 2006 16:31
I know how it is. I live 30 minutes from Deals Gap and we have several that take the medavac ride every weekend it seems. Entry Speed is a mutter Fucker!!!!!!!!!! I'll just be a little slower in and fast as hell mid corner out. It's a lot safer that way
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grunt
Parking Attendant
Posts: 23
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posted September 23, 2006 04:19 PM
Yup- It was 152 and no offence taken. I just lost focus on my riding and got ahead of myself. Ive done Deals Gap a while back...Gunner, you're lucky to live so close. If I remember there are so many hairpins there you're always either leaned over or going straight up a hill. Anyway I'm having fun putting it back together. Its an 06 but since all the front plastic shattered and I like the 04/05 front end better, I'm seeing if I can get an 05 ram air duct to fit the frame and aftermarket skins to go with that.
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1badzx12r
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posted September 23, 2006 05:09 PM
there should be a tree of shame on 152 also...every time i go there somebody's crashed
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http://www.youtube.com/watch?v=S06nIz4scvI
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1badzx12r
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posted September 23, 2006 05:10 PM
but get ur rims miked out for bearings ..the factory bearing are crap anyways
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http://www.youtube.com/watch?v=S06nIz4scvI
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