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Forking Up My FJ

Started by FJ12IRL, April 24, 2018, 02:07:57 PM

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FJ12IRL

Hi All,
I have started to rebuild the front and back end of my '91 FJ and noticed the fork seals are completely shot and were like that long before she came into my possession. I also noticed that the fork stanchions are quite badly pitted with bubbles appearing under the chrome.
I'm now thinking of maybe a complete USD front fork and rear swingarm and wheel transplant from a '92 FZR1000 might work but after a bit of research I can't find any info on it. Has anybody here done it?
Cheers in advance.

Pat Conlon

1) Free Owners Manual download: https://tinyurl.com/fmsz7hk9
2) Don't store your FJ with E10 fuel https://tinyurl.com/3cjrfct5
3) Replace your old stock rubber brake lines.
4) Important items for the '84-87 FJ's:
Safety wire: https://tinyurl.com/99zp8ufh
Fuel line: https://tinyurl.com/bdff9bf3

FJ12IRL

Thanks Pat,
What about the '92 FZR swingarm?
Anyone done that?



FJ12IRL

Hi everyone, since my past post about this I've sourced a 600 Thundercat to use as a donor bike mainly for the wheels and forks. I'm using the FJ triple clamps but I've noticed that they are about 10mm wider than the Thundercats.. Now spacers aren't a problem but I need a longer 17mm diameter axle.. Do any of you guys know of another axle that may fit? I'm thinking an FZR 1000 Genesis might fit, any ideas?

jscgdunn

Best to used the TC forks and triple.  Bolt on and you get a better fender too.
92 FJ1200 2008 ZX14 Forks, wheels, 2008 cbr 600 RR swingarm
92 FJ1200 2009 R1 Swinger, Forks, Wheels, 2013 CBR 1000 Shock
90 FJ 1200 (Son # 2), Stock
89 FJ 1200 Built from parts: (Brother bought it) mostly 92 parts inc. motor
84 FJ 1100 (Son #1), 89 forks wheels, blue spots

FJ12IRL

Quote from: jscgdunn on May 22, 2018, 09:03:45 AM
Best to used the TC forks and triple.  Bolt on and you get a better fender too.

I much prefer the fit and look of the stock FJ triple clamps and bars, the Thundercats clip ons are too weedy in my opinion..

jscgdunn

You can use the FJ handlebars.
92 FJ1200 2008 ZX14 Forks, wheels, 2008 cbr 600 RR swingarm
92 FJ1200 2009 R1 Swinger, Forks, Wheels, 2013 CBR 1000 Shock
90 FJ 1200 (Son # 2), Stock
89 FJ 1200 Built from parts: (Brother bought it) mostly 92 parts inc. motor
84 FJ 1100 (Son #1), 89 forks wheels, blue spots

FJ12IRL

Thanks but they don't  fit the TC top triple, I  tried...

Pat Conlon

If you find a 17mm axle and correct spacer, what's your plan on a fender?
1) Free Owners Manual download: https://tinyurl.com/fmsz7hk9
2) Don't store your FJ with E10 fuel https://tinyurl.com/3cjrfct5
3) Replace your old stock rubber brake lines.
4) Important items for the '84-87 FJ's:
Safety wire: https://tinyurl.com/99zp8ufh
Fuel line: https://tinyurl.com/bdff9bf3

CutterBill

If you need a custom axle, just take the measurements to a machine shop and have them make one. 
Never Slow Down, Never Grow Old.

Current Stable:                                                     
FJ1100                                              
FJ1200 (4)
1999 Yamaha WR400 (street-legal)
2015 Super Tenere
2002 Honda Goldwing

woodcreekpete

Quote from: CutterBill on May 28, 2018, 09:00:46 AM
If you need a custom axle, just take the measurements to a machine shop and have them make one. 
Here's an option for keeping the FJ bars. I wanted to keep them - wasn't too keen on the dogbones or the plate. I had a machinist make up stubs to weld to the tube capnuts (not my welding, used a welder with about 50 years experience - I know my limits!). Cut the clip-ons and made up new locating stubs, welded them top and bottom. Used the existing holes in the triple to locate them. Stepped bushings top and bottom hold the stub bolts very securely. Mechanic, machinist and the welder were all confident of the strength of the set-up.