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General Category => FJ Project Writeups => Topic started by: aussiefj on June 22, 2014, 05:06:13 AM

Title: FZR rims - work in progress
Post by: aussiefj on June 22, 2014, 05:06:13 AM
Hi guys, a few pics of work in progress on the FZR rims. I thought I would take the easy way out and bought a conversion kit from the FJ club in UK and that at least gave me the courage to get started but I've had a couple of minor issues a one possibly major issue with the kit. According to their write up the caliper arm is machine down to 20mm, the one I received was 25mm so I had to get another 5mm taken off. Included in the kit is an Exup sprocket carrier with the seal removed and machined down flush with the bearing, they say you must use the Exup one because if you use the FJ carrier you have to make major mods to the cush drive to get chain alignment, well I,ve compared them side by side, upside down, inside out and I'm buggered if I can find any difference, the carrier from the club is stamped 36Y00, the one that came with the Fzr wheel is 36Y01 and the FJ looks like 36Y01 but the 1 is not properly stamped, so I see no reason why the FJ carrier wont work with the Fzr wheel unless any one here can tell me what the difference is, the model shown in the instructions is an 84/85 alloy swing arm so maybe that's where the confusion is. According to the club with their set up the chain is slightly out of alignment, you have to use a sprocket with off set teeth and turn it around so the offset is on the wheel side to improve alignment, but mine was still about 4mm closer to the swing arm than originally so I decided to get the carrier milled down 4mm where the sprocket mounts and that's where I have the major issue, the sprocket on the carrier from the club was held on by what turned out to be banjo bolts, not only are they hollow but they only have 10mm of thread instead of 20mm. I,m no engineer, and maybe someone on here can tell me otherwise, but that doesn't seem very safe to me, why on earth would you use banjo bolts, if I hadn't decided to get the carrier machined I would never have know until something possibly broke with who knows what consequences, so I thought I would put this out there in case anyone else goes down the same route. Maybe it wouldn't have been a problem, maybe someone here can say if they are strong enough to hold the sprocket in which case it's not an issue. Other than that it's all coming together and I'll update later with photos.
Title: Re: FZR rims - work in progress
Post by: keand3 on June 22, 2014, 06:28:35 AM
Hi Aussiefj.

I too did this mod last year, and bought it from the UK FjClub.
What you say about the sprocketcarrier is true. The FJ and FZR carrier is the same, the only difference is that the one you receive is machined down to make it fit.

Some pictures would be nice though, so we can see more specifically what you are referring to.

The brake toruqearm i received was machined to with the arch that's needed, but i need to grind off some extra make sure the brake disc bolts diden't conflict when spinning.

The banjo bolts will work, but i would rather prefer propper bolts. I had bolt order up as spare that i switched them with. The bolts that followed my kit was s/s bolts that was more then good en ugh.

The alignment is really that an big issue, not for me at least. I replaced the frontsprocket with a rental one which have an small offset. I just turned it around and the offset is now minimal.

I would not recommend grinding the area where the sprocket is bolted on, it might get uneven.. It looks to me that the sprocket carrier you have gotten is not fully grinded to spec for the FZR Exup mod...
Have you complained to the club about the product? It might help giving them a ring or an email. My experiences with them is good, but I know others have had issues.

Cheers
Ken
Title: Re: FZR rims - work in progress
Post by: keand3 on June 22, 2014, 06:30:43 AM
Here's some pictures of the parts I recived.

(http://fjowners.com/gallery/6/2912_15_01_14_1_22_35_6.jpeg)

(http://fjowners.com/gallery/6/2912_15_01_14_1_22_32_5.jpeg)

(http://fjowners.com/gallery/6/2912_15_01_14_1_22_28_4.jpeg)

(http://fjowners.com/gallery/6/2912_15_01_14_1_22_24_3.jpeg)

(http://fjowners.com/gallery/6/2912_15_01_14_1_22_20_2.jpeg)

(http://fjowners.com/gallery/6/2912_15_01_14_1_22_17_1.jpeg)

(http://fjowners.com/gallery/6/2912_15_01_14_1_22_14_0.jpeg)
Title: Re: FZR rims - work in progress
Post by: aussiefj on June 22, 2014, 07:49:02 AM
Quote from: keand3 on June 22, 2014, 06:28:35 AM
Hi Aussiefj.

I too did this mod last year, and bought it from the UK FjClub.
What you say about the sprocketcarrier is true. The FJ and FZR carrier is the same, the only difference is that the one you receive is machined down to make it fit.

Some pictures would be nice though, so we can see more specifically what you are referring to.

The brake toruqearm i received was machined to with the arch that's needed, but i need to grind off some extra make sure the brake disc bolts diden't conflict when spinning.

The banjo bolts will work, but i would rather prefer propper bolts. I had bolt order up as spare that i switched them with. The bolts that followed my kit was s/s bolts that was more then good en ugh.

The alignment is really that an big issue, not for me at least. I replaced the frontsprocket with a rental one which have an small offset. I just turned it around and the offset is now minimal.

I would not recommend grinding the area where the sprocket is bolted on, it might get uneven.. It looks to me that the sprocket carrier you have gotten is not fully grinded to spec for the FZR Exup mod...
Have you complained to the club about the product? It might help giving them a ring or an email. My experiences with them is good, but I know others have had issues.

Cheers
Ken

Hi Ken, that's the same as I received only the caliper arm had only been machined down to 25mm for some reason. Had a look at the photos of your bike, that's a pretty major rebuild mate, fantastic job.
All the best
John