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General Category => FJ Project Writeups => Topic started by: aj52 on November 17, 2017, 12:12:13 PM



Title: West Coast,RSA summer project
Post by: aj52 on November 17, 2017, 12:12:13 PM
Hi all

This afternoon I started to strip the FJ for complete paint job and few machanical stuff like clutch,carbs,valve clearences.
While I'm at it,want to do the coil and headlight mods too.
Maybe it is going to be stupid or simple question,but I want to powdercoat the frame and swingarm. Is there some way or other that I can save the bearings at the linkages and the races on the stearing stem as it is been replaced the beginning of last year.
The wheels' bearings will I replace,as that also going to be powdercoated.

Thanks for any advice
Hannes


Title: Re: West Coast,RSA summer project
Post by: Pat Conlon on November 17, 2017, 12:29:49 PM
Hello Hannes, You should be fine, the curing oven typically gets to 400*F (206*C) Not really that hot.
Clean all the grease out of the bearings, clean, clean... then stuff the openings with aluminum foil to keep the power coat away..

You know the aluminum swing arm from the '89/90 FJ is a great replacement for the steel swinger on the '91-95's

Cheers

Pat


Title: Re: West Coast,RSA summer project
Post by: aj52 on November 17, 2017, 01:06:06 PM
Hi Pat

Thanks for the advice on the powdercoating.
As for the swingarm,I didn't know that,thanks for that as well. I will try and see if I can find one here in SA.
I forgot to mention that the forks also needs to be done. But I think maybe to get front end of an Thunderace. What I understand that it is almost a direct swap. The forks diameter is bigger than the FJ's and make quite a difference.

Hannes


Title: Re: West Coast,RSA summer project
Post by: Pat Conlon on November 17, 2017, 01:27:53 PM
The YZF1000 Thunder Ace (T-Ace) is rare here in the USA, offered only for 1 year (1998) before the more popular YZF R-1 was introduced.
I do not know of any front end conversions using the T Ace forks here in the USA. I do know Dave Carter in the UK did a conversion.
http://www.fjmods.co.uk/ (http://www.fjmods.co.uk/)

For conventional forks the T-Ace is the strongest you will ever get using tree stump 48mm stanchion tubes (vs. the FJ's 41mm)
The T-Ace forks are shorter than the FJ forks, so turn in will be much quicker, but they are full cartridge forks.

Unless you can get a complete clean T-Ace front assembly cheap,  I would look at other USD fork options.

Besides, USD forks gets the chicks....   :gamer:


Title: Re: West Coast,RSA summer project
Post by: aj52 on November 17, 2017, 03:36:27 PM
Pat

Thanks for the link,very interesting to read.
Maybe I must look for the yzf 750 front end.
I want to keep the original handlebar. On the site I see the person made his own adaptor for handlebar.
My father-in-law is an manager at a engineering in town with CNC milling machine. I think he will be able to machine a top yoke for me.
What material are the top yoke,do you maybe know.

Hannes


Title: Re: West Coast,RSA summer project
Post by: aj52 on November 17, 2017, 03:49:02 PM
Pat

Sorry for all the questions. Do you have a write up about your front end swap?
Try to search,but do not find it

Hannes


Title: Re: West Coast,RSA summer project
Post by: Pat Conlon on November 17, 2017, 04:12:48 PM
Alloy 2011 offers good high strength and good machinability.

When you say you want to keep the original handlebar, do you mean the oem FJ bars, or do you have an aftermarket bar on your FJ?

It will be hard to keep the oem FJ bar clamps on your project, unless heavily modified.
The FJ bar clamps to the FJ 41mm dia. stanchion tubes.  There is very little meat on the oem bar clamps to work with....

Most USD upper tubes are 50mm dia, so you can imagine the size difference.
The YZF750R USD upper fork tubes (50mm dia.) do not extend far enough through the top triple clamp to offer a purchase for bar clamps to attach to the tubes, so a handle bar is needed for this conversion.

Giantkiller (Dan) and Aviation Fred both have done GSXR USD fork conversions on their FJ's.
The Suzuki forks are too short for the FJ so Dan has fabricated some trick fork tube extensions which add the necessary length to the GXSR fork tubes.
The new added length extends the GSXR tubes thru the top triple clamp, allowing a "clip on" style bar to attach.
Aviation Fred found some bitchen Tarozzi clip ons he uses on his conversions. Remember, these are sized for a 50mm dia. top tube. http://www.fastfromthepast.com/clip-ons (http://www.fastfromthepast.com/clip-ons)

So, if you do not want a handle bar on your project, and wanted clip on style bars, consider the GSXR swap.

Cheers. Pat


Title: Re: West Coast,RSA summer project
Post by: Pat Conlon on November 17, 2017, 04:17:18 PM
The photos of my bike in the FJ Gallery are old.

I had then the 1992 FZR1000 USD forks : http://www.fjmods.co.uk/usdforks.htm (http://www.fjmods.co.uk/usdforks.htm)

Now I have the 1997 YZF750R USD forks: http://www.fjmods.co.uk/MarcRittner2.htm (http://www.fjmods.co.uk/MarcRittner2.htm)


Title: Re: West Coast,RSA summer project
Post by: aviationfred on November 17, 2017, 11:26:39 PM
Pat has listed the links for the Yamaha USD fork mods.


Here is the write up for the 2008 GSX-R1000 fork mod. http://www.fjowners.com/index.php?topic=16432.0 (http://www.fjowners.com/index.php?topic=16432.0)

A couple of photos of the finished mod.

The 1st photo is the Original modded bike by Dan (giantkiller) The next photos are of my version of the mod that is the result of the link posted above.

Fred


Title: Re: West Coast,RSA summer project
Post by: aj52 on November 18, 2017, 12:46:09 PM
Thanks Fred for the link and foto's
A lot of options between your and Pat's replies.

Hannes


Title: Re: West Coast,RSA summer project
Post by: giantkiller on November 18, 2017, 03:40:09 PM
I used the Ring's from the gsxr clippons to make aluminum bars to the exact spec's as the original Fj bars. The second set I made I tried to make them lighter. And then I bent them so I tried the Apex bars. Very adjustable. But no matter how I adjusted them they placed my hands wider than the stock spec bars that I made.(with a jigsaw and a belt sander). If you want to use the Fj bars. You could cut the stock bars And weld them on to a 50mm steel clamp. Or aluminum the way I did. I'm going to rebuild the second set a little beefier. And put the Apex on the turbo bike. When/if I ever get my house/shop Done.
Don't have a good picture of the bars made but here they are


Title: Re: West Coast,RSA summer project
Post by: aj52 on November 18, 2017, 03:59:01 PM
Thanks for the photo.
Just an question. If I do the gsxr conversion,can I made the fork extender that goes through the yoke,the 50mm at the buttom for forks and the top to fit the FJ original bars

Hannes


Title: Re: West Coast,RSA summer project
Post by: aj52 on November 18, 2017, 04:23:35 PM
Thanks for the photo.
Just an question. If I do the gsxr conversion,can I made the fork extender that goes through the yoke,the 50mm at the buttom for forks and the top to fit the FJ original bars

Hannes

Sorry,that was a dumb-ass question.
Went and look on PC,see what the reason is for not doing that.

Hannes


Title: Re: West Coast,RSA summer project
Post by: aviationfred on November 18, 2017, 04:45:16 PM
Actually, I would imagine that you could. You would have to put a 50mm to 41mm step at the top of the extension. The downside is that the inside diameter of the extentions will be reduced. On the GSXR1000 fork, there are suspension adjustment nuts on the top cap that need access through the extensions. In the photo, you can see the blue adjustment nut.


Fred


Title: Re: West Coast,RSA summer project
Post by: aj52 on November 18, 2017, 05:16:56 PM
Actually, I would imagine that you could. You would have to put a 50mm to 41mm step at the top of the extension. The downside is that the inside diameter of the extentions will be reduced. On the GSXR1000 fork, there are suspension adjustment nuts on the top cap that need access through the extensions. In the photo, you can see the blue adjustment nut.


Fred

Hi Fred

Yes it can be done,but as you said,for adjustment it is going to be an issue.
Not for the adjustment itself,I think, but if you want to change fork springs or change oil,you got to take the forks out for maintenance.
I will see what way I want to go after seeing what is available here in RSA,but many thanks to you,Pat and Giantkiller for the responce and guidelines.

Hannes


Title: Re: West Coast,RSA summer project
Post by: giantkiller on November 18, 2017, 07:42:19 PM
I have a bunch of pictures in my images on the forum here.
But for some reason I can't bring them over to the threads anymore. So I downloaded this from my images to My phone. So I could bring it here
If you blow up the picture you can see I had made some pins to keep the bars from rotating. When raised for touring. But decided not to use them. Just tighten the clamps down and never had a problem. Even when the Deer killed itself on my chest. Didn't move.


Title: Re: West Coast,RSA summer project
Post by: aj52 on November 22, 2017, 12:00:32 AM
Bike is finally totally stripped down.
I am going for the GXSR fork mod as the FJ's forks are badly pitted.
I wanted to put RPM valves in,but because of the pitting aswell,it will increase the cost for repearing to much.

The mod is going to be a cheaper option.
If done some research on the Suzuki between the K5/6 and K 7/8 on Gixxer site. Struggle to get parts for K7/8.
 
Everything has the same numbers,except:
Bottom Fork diameter:K5/6 is 54 mm,K7/8 is 56
Triple clamp offset is:K5/6 is 30,K7/8 is 28
Oil height is:K5/6 is 101 while K7/8 is 124.
Then on top yoke,the ignition switch is in centre as FJ's,while K7/8 is off centre to the left.

Hannes


Title: Re: West Coast,RSA summer project
Post by: aj52 on November 22, 2017, 12:09:21 AM
Hope it uploads


Title: Re: West Coast,RSA summer project
Post by: Pat Conlon on November 22, 2017, 01:01:03 AM
Dan has done his homework on this mod.  :good2:

The GSX-R1000 2007/2008 model years were chosen as donors for a reason.
They have (as oem) the heavier .976kg/mm fork springs which works well with the heavy FJ's.
One less thing to worry about. (Buying New fork springs and rebound/compression valves)
The other year GSXR's used lighter fork springs....fine for a 400lb sport bike, not so good for our's...
http://www.racetech.com/ProductSearch/2/Suzuki/GSX-R1000/2007-08 (http://www.racetech.com/ProductSearch/2/Suzuki/GSX-R1000/2007-08)

Dan and Fred will chime in....

Remember, to think about....what to do with your speedometer.


Title: Re: West Coast,RSA summer project
Post by: aviationfred on November 22, 2017, 02:26:01 AM
I copied this from a post on my fork mod thread that Dan posted.

[/ Just  little on why I went with the 2007-2008 gsxr 1000 front end. I found out that alot of the racers were actually going to lighter springs, that the forks were oversprung from the factory. So I thought they would be good for the heavier FJ. I actually had to soften the preload up when on the FJ. So while I'm no suspension expert.( Actually, I have my racer buddy set them up for my weight. And then fine tune them until I find what I like) But I think they are as good as your going to get. Without changing the springs/valving. After I finished the first one. I thought it handled great... But what did I know. So I had my racer neighbor (was 3rd in points locally for 3 years on his gsxr 1000, anyways not just your average track day racer) take it for a ride. To see if it was any good. Or if I had just made a mess... He wasn't real fired up about it. But agreed to take it for a spin.... He was gone so long I thought he must have crashed. When he finally came driving back up the driveway. I could see a huge grin through the faceshield of his helmet. He got off. And the first thing he said was "I don't know what you did to the geometry. But you got it just right!" He said " I was expecting a big heavy wallowing bike. But this actually turns in better than my Gixxer." He went on to say that he took it on the road he uses to check suspension settings for his race bikes. Corners with stutter bumps. And couldn't get it unsettled. So I know I've stumbled onto something good. (Rear suspension was Honda f4i shock/with 900lb eibach spring and he's 100lb lighter than me) Disclaimer. But the bike/bikes are way better than I can ever push them. Kookaloocolor]


Title: Re: West Coast,RSA summer project
Post by: aviationfred on November 22, 2017, 02:30:00 AM
Here is a parts list that I made of what is needed to do the GSX-R1000 front end mod. These parts will give you a 100% identical front end as the 3 FJ's that Dan (giantkiller) and the 1 FJ that I have done.


Here is the itemized list of the parts required for this mod. I have done my best to identify all models and years that the parts can be sourced from. If the parts states only 2007/2008 GSX-R1000, than I highly recommend only using the part from that model and years.


Front wheel          2005-2008 GSX-R1000, 2006/2007 GSX-R750, 2006/2007 GSX-R600

Forks                   2007/2008 GSX-R1000

Rotors                  2007/2008 GSX-R1000

Calipers                2005-2008 GSX-R1000, 2006/2007 GSX-R750, 2006/2007 GSX-R600

Fender                  2007/2008 GSX-R1000, 2008/2009 GSX-R750, 2008/2009 GSX-R600

Top Yoke               2007/2008 GSX-R1000
upper triple clamp

Steering stem        2007/2008 GSX-R1000
lower triple clamp

FJ Steering Stem    1984-1990 interchange, 1991-1993 interchange only with said years.

FJ Steering Stem    all years, Items 3-7 in the parts breakdown diagram
Hardware

Handle Bars           Tarozzi clip ons, 50mm diameter, 70mm rise

Brake line              Spiegler Stainless steel braided, Single line 820mm length with 20 degree banjo fittings. The length and fittings may vary due to the type of master cylinder used.

Suzuki crossover    2005-2008 GSX-R1000, 2006/2007 GSX-R750, 2006/2007 GSX-R600
brake line

Bar ends                HVMP heavy weight (14oz.) each. pressure lock style

Fender bolts           6 total, the 4 forward bolts are one part number and the aft 2 bolts are a another part number. The parts diagram only says 2 required for the forward mount. Order 4. These can be found
                             in titanium

Caliper bolts           4 total, these can be found in titanium

Rotor bolts             10 total, I used titanium, slightly less weight, reducing rotating mass

Fork Extensions      Custom fabricated to Dan McCoy's (giantkiller) specs. Purchased as finished items from Dan.

Top Yoke Bushing    Locally fabricated.

I left out hand grips, brake pads as the type and brand used is a personal choice.

Over all this mod is fairly straight forward. For skills required, If you can change your own fork seals, than this mod is in reach of your skills. Very minor machine work is required. I don't have the equipment to do this and I outsourced the work. The steering stems are pressed out of the lower triples. The FJ stem requires the lower end to be very slightly enlarged by adding some weld. Then turned down and press fit into the Suzuki lower. The top yoke bushing is simply to take up space between the two upper threaded areas and the hole in the Suzuki yoke.

I hope this helps anyone else that is interested in doing this.


Fred


Title: Re: West Coast,RSA summer project
Post by: aj52 on November 22, 2017, 02:33:44 AM
Hi Pat & Fred

According to that chart,the spring rates are the same,just the lenght that differs.
The chart is a bit dull. I got it at www.gixxer.com/forums (http://www.gixxer.com/forums).

Thanks Fred for the list


Title: Re: West Coast,RSA summer project
Post by: aviationfred on November 22, 2017, 02:37:10 AM
I myself am beginning this same mod again. I have begun ordering the parts I need. I will proceed with the install after the first of the year, once the weather gets cold.

Here is the front wheel in my living room, waiting to be installed.

Something that I did not have listed is a 90 degree valve stem. The rotors are 310mm Dia. leaving the straight valve stems installed makes checking tire pressure a pain in the rear and getting an air chuck positioned to add air even more frustrating.


Fred


Title: Re: West Coast,RSA summer project
Post by: aj52 on November 22, 2017, 07:05:58 AM
Hi Fred

I've read about the FJ that you had done this mod on,has been stolen.
Good to see that you at it again to do another one.
 
Dan,
Can you please give me the dimensions on the fork extenders that you have manufactured for Fred and yourself.


Thanks
Hannes


Title: Re: West Coast,RSA summer project
Post by: aj52 on November 27, 2017, 04:57:12 AM
Hi everyone

I went for the R1 front end as I couldn't get K7/8 parts here in RSA.
Know I probably need to get stiffer fork springs,but will adress that later.
Bottom triple in for the steering stem to be machined.
Going to use FJ's top triple,has the same offset as the R1.
The fork extender s will be fabricated according to that. By doing this,I can use original clamps. And steering lock will still be functional.

Hannes


Title: Re: West Coast,RSA summer project
Post by: giantkiller on November 27, 2017, 06:20:50 AM
Hi everyone

I went for the R1 front end as I couldn't get K7/8 parts here in RSA.
Know I probably need to get stiffer fork springs,but will adress that later.
Bottom triple in for the steering stem to be machined.
Going to use FJ's top triple,has the same offset as the R1.
The fork extender s will be fabricated according to that. By doing this,I can use original clamps. And steering lock will still be functional.

Hannes

Sorry Hannes I don't have a set on hand and have Long since lost the plans I had drawn up. I just order a set from the machinist. He has saved the program for the CNC machine. He has a spare set right now but I'm sure shipping would be prohibitive.


Title: Re: West Coast,RSA summer project
Post by: Pat Conlon on November 27, 2017, 11:15:29 AM
Hey Dan...Shipping may be expensive to South Africa but, it is what it is, you have the only sets of these extenders available in the world.


Title: Re: West Coast,RSA summer project
Post by: FJmonkey on November 27, 2017, 11:23:29 AM
Sorry Hannes I don't have a set on hand and have Long since lost the plans I had drawn up. I just order a set from the machinist. He has saved the program for the CNC machine. He has a spare set right now but I'm sure shipping would be prohibitive.
Dan, I can reverse engineer that set if they are not needed right away.


Title: Re: West Coast,RSA summer project
Post by: aviationfred on November 28, 2017, 05:03:24 AM
Sorry Hannes I don't have a set on hand and have Long since lost the plans I had drawn up. I just order a set from the machinist. He has saved the program for the CNC machine. He has a spare set right now but I'm sure shipping would be prohibitive.
Dan, I can reverse engineer that set if they are not needed right away.


Mark,

I actually have set of Dan's extensions that are not yet in use.


Fred


Title: Re: West Coast,RSA summer project
Post by: giantkiller on November 28, 2017, 07:17:12 AM
Thanks Fred I didn't want to say anything for you. The only thing I have access to are the extensions I had welded on and machined down.


Title: Re: West Coast,RSA summer project
Post by: FJmonkey on November 28, 2017, 09:37:59 AM
Well.... Get on with it then. You have my address Fred. Then we can add one gem for to the files section.


Title: Re: West Coast,RSA summer project
Post by: aj52 on November 28, 2017, 03:09:24 PM
Sorry Hannes I don't have a set on hand and have Long since lost the plans I had drawn up. I just order a set from the machinist. He has saved the program for the CNC machine. He has a spare set right now but I'm sure shipping would be prohibitive.
Dan, I can reverse engineer that set if they are not needed right away.


Mark,

I actually have set of Dan's extensions that are not yet in use.


Fred

Fred,

With Dan's permission,can you please give me dimensions of the piece?
The outside diameter of piece that goes over fork and the wall thickness of that piece.(inside diameter is 50mm).
The length of bigger piece where it start to recess.

The OD off recess part is 50mm.
What is the wall thickness on recess part.

Dan

If it is all right and in order with you,may Fred give me the dimensions on the extenders please?

Thanks
Hannes


Title: Re: West Coast,RSA summer project
Post by: FJmonkey on November 28, 2017, 04:00:03 PM
I have the concept, I just need to verify the machining details and dimensions so I can make a proper drawing.


Title: Re: West Coast,RSA summer project
Post by: aj52 on November 28, 2017, 04:11:53 PM
I have the concept, I just need to verify the machining details and dimensions so I can make a proper drawing.

Thanks Mark

The idea that I have for using OEM clip-ons, is to machine a 41mm OD piece which threads into the extender piece. So when one wants to make adjustments on the forks,you can just take off clip-ons,unscrew the 41mm piece to gain access to the top of the fork.
This is only an idea that I have,hope it will be feasible.

Hannes


Title: Re: West Coast,RSA summer project
Post by: FJmonkey on November 28, 2017, 04:55:03 PM
Thanks Mark

The idea that I have for using OEM clip-ons, is to machine a 41mm OD piece which threads into the extender piece. So when one wants to make adjustments on the forks,you can just take off clip-ons,unscrew the 41mm piece to gain access to the top of the fork.
This is only an idea that I have,hope it will be feasible.

Hannes
So the part that the bars clamp on to are threaded into the GSXR adapter. Do you have an idea how to keep the threads from turning when there is a load on the bar like hard braking?


Title: Re: West Coast,RSA summer project
Post by: aj52 on November 28, 2017, 05:07:11 PM
Mark

The OEM clip-ons for the FJ has an hole for allen-cap bolt that threads into yoke. Won't that prevent the clip-ons from moving for hard braking etc.?




Title: Re: West Coast,RSA summer project
Post by: aj52 on November 28, 2017, 05:12:03 PM
Mark

The OEM clip-ons for the FJ has an hole for allen-cap bolt that threads into yoke. Won't that prevent the clip-ons from moving for hard braking etc.?




Or make a shoulder on the piece and cut an recess at bottom of clip-ons so that it is flush. Say about 2mm or so.
That will also prevent piece from turning

Hannes


Title: Re: West Coast,RSA summer project
Post by: giantkiller on November 28, 2017, 06:34:30 PM
Yes I'm not making any money off them. I just think it's cool that something I came up with an improved on with the second generation is something good and others can use. Be sure to put the bolts in from opposite sides for the 2 pieces. Makes it more convenient to get at the Allen's.  The machinist only had access to black Allen's. I put stainless ones in.

Hannes. Like I said I made the little extensions for the locating pins for the clippons. When up in touring position.
But I decided not to use them. As long as you have the clamps tight on the top triple and the clamps for the clippons. They won't rotate. I bent the second set of aluminum ones I made too thin (thinking lighter is better) and didn't rotate them. And I had the deer commit suicide on my chest and didn't rotate them. But it would be simple like you said to lock them in place. The Gixxer clippons just have a pin that goes into a hole in the top triple clamp. If you blow up the picture of the clippons I made. You can see the extensions I made for the pins.(actually look like miniture fork extensions)


Title: Re: West Coast,RSA summer project
Post by: aj52 on November 28, 2017, 06:52:37 PM
Thanks Dan for the permission. Your design looks much better than the one's on the web.
I will look what to do when I receive the triple's back from my father-in-law(my machinist). He is doing it for me,just needs to buy the materials and something to keep his throat wet while he is busy with machining.
 
What is the c-c distance of the FJ's top triple. Know the offset is 35mm. All the parts are with him for the stem to be machined and press fit and to make the spacer on top triple


Title: Re: West Coast,RSA summer project
Post by: aj52 on November 28, 2017, 09:44:50 PM
Found the c-c of the FJ,it is 210mm according to Tarossi(www.fastfromthepast.com (http://www.fastfromthepast.com)).
The R1('98-01) parts that I've got last weekend for front-end,has the same c-c on front-end as well as same offset.


Title: Re: West Coast,RSA summer project
Post by: aviationfred on November 28, 2017, 11:05:35 PM
I did find another handle bar option.... The downside is..... It is the most expensive option. Here is the link.

https://m.ebay.com/itm/Superbike-Handlebars-Conversion-KIT-SUZUKI-GSX-R-1000-01-08-BLACK-ANODISED-/272644669188

The first photo is of the Superbike bar conversion.

The second photo is from my fork conversion using the Tarozzi handle bars from Fastfromthepast.com. They are close to being half the cost of the superbike conversion. During the time that I had the USD forks. I never had movement with the Tarozzi bars. To verify this, I put a black paint stripe on the clamp area and the adaptor.


Fred


Title: Re: West Coast,RSA summer project
Post by: aj52 on November 29, 2017, 06:13:50 AM
Received the triple's and stem today.
The spacer that comes between stem and top triple.
Forget what machinist called the process on the stem to make it not turning in lower triple,but it wasn't necessary to weld up and machine it down again to fit tight. This is what he has done to it


Title: Re: West Coast,RSA summer project
Post by: jscgdunn on November 29, 2017, 08:01:07 AM
Aj,
Just bit of advice.  I have done two USD front end conversions, one with an 2008 R1 front end, and one with a 2008 ZX14 front end.  For the R1 I used an FZ1 top triple and bars; this worked out well.  For the Zx14 I have a modified ZX14 top triple and LSL bars.  Not so great....I am on my second set of bars. 

If I had a "do over", I would go with the adjustable clip on bars like Fred did along with Dan's extensions.  This approach gives much more flexibility as you will need to manage interference points between the tank and fairing and find a good riding position.  My thoughts.

On the bottom triple, in the R1 case, my machinist had to lengthen the FJ stem (as it appears in your pic) and then press in.  This allows for the greater thickness of the R1 bottom triple. 

In the ZX14 case, the ZX14 stem can be used by using the bottom Zx14 bearing and race.  The top of the stem needs to be turned down to fit the top FJ bearing.

I found the R1 fork springs were fine, but I did have to replace the ZX14 springs as they were too soft.

Jeff



Title: Re: West Coast,RSA summer project
Post by: aj52 on November 29, 2017, 03:37:07 PM
Aj,
Just bit of advice.  I have done two USD front end conversions, one with an 2008 R1 front end, and one with a 2008 ZX14 front end.  For the R1 I used an FZ1 top triple and bars; this worked out well.  For the Zx14 I have a modified ZX14 top triple and LSL bars.  Not so great....I am on my second set of bars.  

If I had a "do over", I would go with the adjustable clip on bars like Fred did along with Dan's extensions.  This approach gives much more flexibility as you will need to manage interference points between the tank and fairing and find a good riding position.  My thoughts.

On the bottom triple, in the R1 case, my machinist had to lengthen the FJ stem (as it appears in your pic) and then press in.  This allows for the greater thickness of the R1 bottom triple.  

In the ZX14 case, the ZX14 stem can be used by using the bottom Zx14 bearing and race.  The top of the stem needs to be turned down to fit the top FJ bearing.

I found the R1 fork springs were fine, but I did have to replace the ZX14 springs as they were too soft.

Jeff



Hi Jeff

Thank you for your input and advice on the top triple between the 2 different modifications.
I searched the info on FZ1 top triple as you suggested. It has an offset of 25mm,same as the '08 R1.
The '98-'02 R1 front-end that I have,has an 35mm offset,same as the FJ.
I'm going to fit the front-end tomorrow to get measurements for fork extenders,modify ignition switch and the stops.
Going to use the R1 top triple.
The handlebars will be sort out when I start assembling after the powdercoating of the frame and swingarm.

Hannes


Title: Re: West Coast,RSA summer project
Post by: The General on November 29, 2017, 08:49:37 PM
Aj,
Just bit of advice.  I have done two USD front end conversions, one with an 2008 R1 front end, and one with a 2008 ZX14 front end.  For the R1 I used an FZ1 top triple and bars; this worked out well.  For the Zx14 I have a modified ZX14 top triple and LSL bars.  Not so great....I am on my second set of bars.  

If I had a "do over", I would go with the adjustable clip on bars like Fred did along with Dan's extensions.  This approach gives much more flexibility as you will need to manage interference points between the tank and fairing and find a good riding position.  My thoughts.

On the bottom triple, in the R1 case, my machinist had to lengthen the FJ stem (as it appears in your pic) and then press in.  This allows for the greater thickness of the R1 bottom triple.  

In the ZX14 case, the ZX14 stem can be used by using the bottom Zx14 bearing and race.  The top of the stem needs to be turned down to fit the top FJ bearing.

I found the R1 fork springs were fine, but I did have to replace the ZX14 springs as they were too soft.

Jeff



Hi Jeff

Thank you for your input and advice on the top triple between the 2 different modifications.
I searched the info on FZ1 top triple as you suggested. It has an offset of 25mm,same as the '08 R1.
The '98-'02 R1 front-end that I have,has an 35mm offset,same as the FJ.
I'm going to fit the front-end tomorrow to get measurements for fork extenders,modify ignition switch and the stops.
Going to use the R1 top triple.
The handlebars will be sort out when I start assembling after the powdercoating of the frame and swingarm.

Hannes
MINE has a really terrible turning circle. (R1 early model front end). Interested to hear how yours is. Looking at ways to improve.


Title: Re: West Coast,RSA summer project
Post by: aviationfred on November 29, 2017, 11:06:46 PM
Aj,
Just bit of advice.  I have done two USD front end conversions, one with an 2008 R1 front end, and one with a 2008 ZX14 front end.  For the R1 I used an FZ1 top triple and bars; this worked out well.  For the Zx14 I have a modified ZX14 top triple and LSL bars.  Not so great....I am on my second set of bars.  

If I had a "do over", I would go with the adjustable clip on bars like Fred did along with Dan's extensions.  This approach gives much more flexibility as you will need to manage interference points between the tank and fairing and find a good riding position.  My thoughts.

On the bottom triple, in the R1 case, my machinist had to lengthen the FJ stem (as it appears in your pic) and then press in.  This allows for the greater thickness of the R1 bottom triple.  

In the ZX14 case, the ZX14 stem can be used by using the bottom Zx14 bearing and race.  The top of the stem needs to be turned down to fit the top FJ bearing.

I found the R1 fork springs were fine, but I did have to replace the ZX14 springs as they were too soft.

Jeff



Hi Jeff

Thank you for your input and advice on the top triple between the 2 different modifications.
I searched the info on FZ1 top triple as you suggested. It has an offset of 25mm,same as the '08 R1.
The '98-'02 R1 front-end that I have,has an 35mm offset,same as the FJ.
I'm going to fit the front-end tomorrow to get measurements for fork extenders,modify ignition switch and the stops.
Going to use the R1 top triple.
The handlebars will be sort out when I start assembling after the powdercoating of the frame and swingarm.

Hannes
MINE has a really terrible turning circle. (R1 early model front end). Interested to hear how yours is. Looking at ways to improve.

I agree, this is an unfortunate side effect. With the combination of the 50mm fork leg and the additional thickness of the extention, I positioned the extention in a way that the flange for the pinch bolts were facing in towards each other. This allowed the smooth part of the extention to contact the frame near the steering head as a steering stop. Steering radius IS GREATLY REDUCED.

Fred


Title: Re: West Coast,RSA summer project
Post by: aj52 on January 17, 2018, 07:11:21 AM
Just an update on project.

The frame and swingarm are in for sandblasting and powdercoating on Monday(businesses only open on up after the holidays on Monday).
I went for matt black.

I removed the bearings on the swingarm as I think it is time for new ones.
The top steering bearings are toasted after only about an year and half,so replacing that also(water damage).

I ran into a problem with availability on swingarm bearings.
So my question is as follows:
The bearings # that I removed are: BHKM 1730 JU(Koyo) and other is TA 2530 Z (IKO).

The ones that I can locate here are both 15mm in length,it should be 30mm.
The sales rep suggested that I then use 2 bearings to make up the length.
Can I do that? I don't want to waste money on bearings that will give me trouble along the way.
Or maybe someone knows of alternative bearing #( Timken,SKF,NSK)for the swingarm.

Thanks
Hannes


Title: Re: West Coast,RSA summer project
Post by: Pat Conlon on January 17, 2018, 07:38:52 PM
The Partzilla page on the 1992 FJ swing arm shows the bearings still available from Yamaha.
https://www.partzilla.com/catalog/yamaha/motorcycle/1992/fj1200ad/swing-arm (https://www.partzilla.com/catalog/yamaha/motorcycle/1992/fj1200ad/swing-arm)


Title: Re: West Coast,RSA summer project
Post by: aj52 on January 18, 2018, 04:57:20 AM
The Partzilla page on the 1992 FJ swing arm shows the bearings still available from Yamaha.
https://www.partzilla.com/catalog/yamaha/motorcycle/1992/fj1200ad/swing-arm (https://www.partzilla.com/catalog/yamaha/motorcycle/1992/fj1200ad/swing-arm)


Thanks Pat


Title: Re: West Coast,RSA summer project
Post by: aj52 on January 20, 2018, 08:12:27 AM
Powdercoated frame


Title: Re: West Coast,RSA summer project
Post by: aj52 on January 20, 2018, 08:15:18 AM
Powercoated swingarm


Title: Re: West Coast,RSA summer project
Post by: Pat Conlon on January 20, 2018, 02:28:46 PM
Hannes, the 2 pdf's (above) are the same picture of your swing arm and lower frame cradle. (looking good!)

Also, check out RPM's offerings on swing arm goodies. They ship to RSA
 http://rpmracingca.com/search.asp?pg=1&stext=swing+arm&sprice=&stype=&scat=&sfil0= (http://rpmracingca.com/search.asp?pg=1&stext=swing+arm&sprice=&stype=&scat=&sfil0=)


Title: Re: West Coast,RSA summer project
Post by: aj52 on January 20, 2018, 03:48:42 PM
Hannes, the 2 pdf's (above) are the same picture of your swing arm and lower frame cradle. (looking good!)


Thanks Pat,did not notice that I have loaded same photo twice.
For the one or other reason I don't know why,I must convert photo's to pdf as it doesn't want to upload jpg files.
Here are the frame.




Title: Re: West Coast,RSA summer project
Post by: giantkiller on January 20, 2018, 04:39:25 PM
Hannes, the 2 pdf's (above) are the same picture of your swing arm and lower frame cradle. (looking good!)


Thanks Pat,did not notice that I have loaded same photo twice.
For the one or other reason I don't know why,I must convert photo's to pdf as it doesn't want to upload jpg files.
Here are the frame.
I can't get photos to upload anymore either. I can to all the other forum's I belong too. And anywhere else for that matter. Just can't here anymore.



Title: Re: West Coast,RSA summer project
Post by: aj52 on January 23, 2018, 12:12:37 AM
Received the fork extenders from father-in-law.
Want to powdercoat it gold as the forks,if they have gold available


Title: Re: West Coast,RSA summer project
Post by: aj52 on February 08, 2018, 02:28:49 PM
Front end fitted today.


Title: Re: West Coast,RSA summer project
Post by: FJmonkey on February 08, 2018, 03:10:25 PM
Looking good.


Title: Re: West Coast,RSA summer project
Post by: fj1289 on February 08, 2018, 03:58:53 PM
Clever way to retain the stock top clamp - and stock ignition switch and fork lock


Title: Re: West Coast,RSA summer project
Post by: aj52 on February 08, 2018, 04:21:42 PM
Clever way to retain the stock top clamp - and stock ignition switch and fork lock

Yes,luckily it work out that way. I took a change to let the extenders be manufactured that way. I am using the stock clip-ons as well. So it is just the bottom triple tree of the R1 that I am using,with the FJ stem pressed into it.

Here are the dimensions for the extenders. The OD of piece that goes over the forks,is 60mm,enough space between frame and extenders.


Title: Re: West Coast,RSA summer project
Post by: aj52 on February 08, 2018, 04:25:30 PM
Looking good.

Thanks Mark.
I wil repaint engine this coming December,as it look a bit of neglected in comparison with frame


Title: Re: West Coast,RSA summer project
Post by: FJmonkey on February 08, 2018, 04:35:59 PM
Thanks for posting the dimensions. I can finish my solid model and publish some engineering drawings for others with Moditus and Crack habit like budget.


Title: Re: West Coast,RSA summer project
Post by: andyoutandabout on February 10, 2018, 12:07:02 AM
Oooh what a lovely black frame. I’m sure a powder coat will hold up well over time. I sprayed mine with truck bed liner, which produced a rather pleasing texture that hasn’t chipped at all in the two years since. Also did the engine in that VHT high heat BBQ paint, and that’s held up well too. The only part that looked tatty after the first year was the swing arm. Think chain lube pulled off the truck bed liner. That problem got solved by a generous, immaculately coiffured FJer and a polished unit.
Carry on projecting



Title: Re: West Coast,RSA summer project
Post by: aj52 on March 03, 2018, 08:04:26 PM
Almost a month since last posting.
I didn't done much the past few weeks because of work.
Wire harness are in and connected.

But......

Because of taken much longer than I have planned for project,I went yesterday and bought a 2nd FJ.



Title: Re: West Coast,RSA summer project
Post by: aj52 on April 27, 2018, 12:49:26 PM
Oooh what a lovely black frame. I’m sure a powder coat will hold up well over time. I sprayed mine with truck bed liner, which produced a rather pleasing texture that hasn’t chipped at all in the two years since. Also did the engine in that VHT high heat BBQ paint, and that’s held up well too. The only part that looked tatty after the first year was the swing arm. Think chain lube pulled off the truck bed liner. That problem got solved by a generous, immaculately coiffured FJer and a polished unit.
Carry on projecting



I bought Rust Oleum Hi Heat Ultra. They say it withstands temperature up to 648ºC (1200 degrees).
It is an BBQ paint with a smooth finish.
I want to paint it this weekend.
The aluminium pieces has pitmarks,will see how I am going to remove those marks.
The clearcoat for the aluminium can withstand 120ºC,will it last with that paint. Can't find other clearcoat with higher temperature resistance.

Hannes


Title: Re: West Coast,RSA summer project
Post by: aj52 on May 26, 2018, 05:15:34 AM
Found a bike shop in Cape Town that can supply me with 18 front sprockets and  38 rear sprockets for the GSXR rear wheel,so it save me a lot of $$$,no need for import costs.
What I also like about this place is that they have a lot of FJ parts as well that I couldn't found at the bigger shops in RSA.
Just a shame that they don't have plastic parts as well,that would have been a great found.


Title: Re: West Coast,RSA summer project
Post by: aj52 on June 22, 2018, 11:24:44 AM
What is the best option for the brake lines,the 2 lines direct from master or the one with the splitter in between as it is OEM?
If the 2 lines option is better,can someone give me the lenght of the lines.

Thanks
Hannes


Title: Re: West Coast,RSA summer project
Post by: FJmonkey on June 22, 2018, 01:49:27 PM
Recent posts report that a fork brace can contact the splitter under full compression causinf loss of front braking. So if you plan to keep the OEM size forks, a fork brace is a really good idea. Less connections in any hydraulic line is also a good idea. As far as length goes, one line that is as long as the two you are removing will work. This assumes both lines run up the center like where the splitter is. Lets see who has better info on the length(s) you need.


Title: Re: West Coast,RSA summer project
Post by: aj52 on June 22, 2018, 09:31:49 PM
Recent posts report that a fork brace can contact the splitter under full compression causinf loss of front braking. So if you plan to keep the OEM size forks, a fork brace is a really good idea. Less connections in any hydraulic line is also a good idea. As far as length goes, one line that is as long as the two you are removing will work. This assumes both lines run up the center like where the splitter is. Lets see who has better info on the length(s) you need.

Thanks for the reply.
I've done an R1 front end swap,don't need do have an fork brace(I think I don't need it). As far as I've searched,no one that has done the upside down mods,mentioned that they use fork braces.
I'm just a bit cautious about the lenghts of the lines,that's why I asked about right length for those who have done swaps.


Title: Re: West Coast,RSA summer project
Post by: Pat Conlon on June 23, 2018, 12:16:57 AM
With a USD swap, be safe and measure the lines yourself.

Take 2 pieces of #12 or #14 electrical wire (single conductor) and connect them to the banjo bolts at the m/c and calipers. Trim to fit.
Check for anywhere they could scuff. Leave some slack for the fork extension.

You have special forks, be wary of measurements from standard FJ forks.
 To prevent any line twist, get lines where you can clock (twist) the banjos


Title: Re: West Coast,RSA summer project
Post by: oldktmdude on June 23, 2018, 05:07:56 PM
   Make sure you measure with the forks at the end of their travel. Raise the front of your bike off the ground, then measure.
   Regards, Pete.


Title: Re: West Coast,RSA summer project
Post by: aj52 on June 25, 2018, 03:19:23 PM
Thanks Pat & Pete

Will measure it as you suggested.