Are the forks on the 03-04's the same size as the 05-06's?

 

Nope, completely different.

 

No they are not. I believe that in 05 they switched from standard forks to inverted forks.

 

that would explain why the clip on i got from an 03-04 didn't work on my 06, damn! thanks for the help

 

Yes, they inverted the forks in 2005 but you can mount them on a 2003-2004 600 RR, which is my next big upgrade.

Check this link:
http://www.600rr.net/vb/showthread.php?t=101981

 

jfunk, what do you need to replace those forks? Just the upper and lower triple clamps? Do the steering bearings remain the same?

 

Surfn...If you read the link above, this guy laid out everything for you...I would use whatever neck bearings comewith the new forks...I have found multiple sellers on 600RR.net that have full front ends for sale and will sell everything needed for around $500.


What parts will I need?The 05-06 front end swaps straight onto the 03-04 neck, so no special parts are needed.

These parts from your 03-04 can be reused:
*03-04 Wheel & Rotors
*03-04 Controls (throttle, starter module, high/low beam switch, etc)
*03-04 Neck bearings, bearing races, and dust covers (internals of neck)
*03-04 Axle
*03-04 Brake Master Cylinder
*03-04 Ram Air Covers (will need to be trimmed)

These parts from the 05-06 are needed for the conversion:
*05-06 Fork tubes
*05-06 Lower triple clamp (with neck)
*05-06 Upper triple clamp
*05-06 Clip-ons (will also need a new grip for left clip-on, more on that later)
*05-06 Wheel spacers
*05-06 Brakes (calipers, pads, lines)
*05-06 Front Fender