FZR600 Front End
Removing the RZ350 Original Forks
Removing the old front forks is a pretty straightforward project but I thought I'd post it here just to make things consistent through this site. My old forks were definitely in need of some help as I found that they were starting to leak at the seals once I had them removed. First place the bike on the main stand, and have a crate or some sort of other support ready for when the front wheel is removed.
The first step is to remove the brake calipers because they sit to far inwards to let the front wheel pass between them. To remove them, simply unbolt the two bolts which connect them to the forks. Unhook the brake lines from the fender clips. They can then be swung out of the way and either zip tied, or simply wedged in the frame and out of the way.
Next, remove the split pin on the axle not on the left side of the front wheel and disconnect the speedometer cable which attaches to a small hub just beyond the bottom of the left side fork. Once removed the axle can be dislodged towards the right side, and the entire front wheel can be removed with the rotors attached. Have a helper give you some assistance at this stage as the bike can easily lean forwards without the wheel in place, and drop off the main stand.
The balance of your bike will depend on how much fuel is on board, but I found that my bike would try and drop on to the forks with the slightest pressure. You can remove the tank to get the balance more on the rear wheel, or simply put something under the forks so an unexpected drop forwards only hits the support and doesn't drop the bike.
To remove the front fender, you need to remove 4 bolts that attach it to the forks. These bolts also connect the brake line clips which will fall away from the fender once the bolts are removed.
Now that the front fender is out of the way I focused on the controls and triple clamps. My FZR conversion has the same switch gear and handlebar diameter as the RZ so I didn't have to disconnect the throttle or clutch, but I did have to remove the handlebars in order to slide them off still connected to the controls. Using a hex key, remove the four bolts on the handlebar risers. Sliding the controls off is as easy as loosening the pinch bolts and off they came. I stuffed them back in the frame to keep them out of the way.
Then disconnect the tachometer drive from the back of the gauge cluster. If the speedo cable is still attached it can also be removed and pulled clear of the bike.