Something that I see often overlooked is that before a fork swap is the replacement forks often need springs and a revalve. This is certainly the case with Hayabusa forks. The internal valving is crap and the springs are on the soft side for many riders.

Please don't get fooled into thinking straight out of the box the inverted forks will be better. Sure, they are probably better than the stock VTR forks. In most cases doing springs and revalve on your VTR forks will net you better performance than a set of stock inverted forks.

So for someone who rides about 600 miles a year and not extreemly agressive, youre saying reworking stock forks will suffice? im 205 at 5'11'' and my current forks bottom out extreemly easy. its a 98 model and i dont know if previouse owners ever serviced them.

I had reworked stock forks on my '98 that saw street and track duty and having them simply resprung and correctly valved made a world of difference (I'm also 200-ish)

Yeah, for most riders a revalve/spring upgrade is plenty. USD forks are nice but I'm not sure the average rider would be able to justify the cost.

ZX10r Fork swap
 

Hello all
I am working on a fork swap using 04/05 ZX10r forks & calipers, 07 CBR600rr triples and a GSXR1000 radial mastercylinder.
This puts the brake caliper centres at 132mm, and the 04/05 ZX10r axle is the same diameter as the VTR's.
VTR brake disc centres are at 130mm, which is ok. Floating piston calipers allow for such discrepancies.
With this setup I can use the stock wheel. I'm working on spacer sizes now.
The top triple had to be bored out to 50mm, bottom was fine. Bearings and spindle were the same. I will have to adjust the steering stops as they don't allow enough lock, and then I will need to put the radiator spacers on.
With the downward gullarm top triple the forks are long enough.
The brakes on that model of ZX10r were known to be soggy, and that mastercylinder is a known fix on the zx forum.
More to follow.

I just found my triple clamp set from my old TLR in teh shed - I'm going to see if they'll fit on the Hawk

So the fitment holes are same spacing on the SP-1 discs(rotors) as the 954?

Bolt spacing is the same across many models and years. Take a look at these charts.
Attachment 20292

Attachment 20293

That's perfect, thank you :)

Has anyone ever determined which of the fork swaps is the lightest?

I am running 2005 ZX-10R forks and had read at the time of their release that they were the lightest USD forks around. That may or may not be the case anymore.