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[ZOA NOM]

Damn Robert, that's a lot of plastic repair for a machine with just 3k miles.

Rick, where is it sold locally or is it an online purchase?

Joe

I think I got it off Amazon

Amazon Link

[RPM - Robert]

Damn Robert, that's a lot of plastic repair for a machine with just 3k miles.

I do not recall the whole story. But it was something like the bike got dropped off and the mechanic wanted to take it for a test ride. I think he said it was on the ground before he left the parking lot.

The carbs were destroyed as well, I don't know if it was the same mechanic or not but they busted off ALL of the float pin towers inside the carb body. That was one of the reasons for such a long haul trip. He had, had the bike to several different places and none of them could get it running and some of them wouldn't even touch it to begin with. I told him we could get it running, most likely in about 30 minutes, if the bike was running when he parked it and the tank was clean it was most likely carbs; unless one of the other mechanics did some crazy diagnosis and opened the motor up for some reason but with so little miles on her, I was pretty confident.

The first thing we did when he got here was put her up on the lift took a set of carbs of one of our bikes and installed on his bike, hooked up a fresh battery, and she started right up. At that point he said that he knew he had made the right choice.

[Pat Conlon]

....and then the mods began...

Bwhahahaha

[RPM - Robert]

Yea, basically, at that point we told him we could put a new set of carbs on it, the new battery, some fresh oil, and new tires and he could head home. BUUUUUUUTTTTTTTTTTTTTT he said he wanted the USD so he could get the chicks. And now here we are.

[Pat Conlon]

Yes indeed...however...He has to have the bike back before he gets the chicks....

The USD's are the easy part (nice solution on the stem).....figuring out the shock and linkage on the R1 swinger is the hard part.

Take lot's of pictures Robert. It's a cool project.

BTW, reminds me, check with your dad when you get a chance, he mentioned something about getting some custom steering stems made that would help us with the YZF USD conversions (instead of having to weld the FJ stem, then machine down the diameter to fit the YZF lower tree)

Cheers laddie, stay warm! 

[Tuned forks]

Good to read about this project again.  I hope he has another motorcycle to ride while the FJ is in RPM jail.

Cheers laddie, stay warm! 

Yeah, no kidding Pat.  Unless Robert has a heater it's probably colder than a well digger's a$$ in that shop.

Joe

[racerrad8]

It has been a while since we have made any progress on the FJR1.

But work has been slowly progressing. The shock has finally been worked through. The shock that Tim purchased is no longer available. So, after getting shock bodies, shafts and springs we were finally able to work to a finished product. Unfortunately, the upper shock mount has to be modified to clean the attached reservoir. So, we are working through that now for the final set up.

The R1 Linkage looks like it might be right in the acceptable range. If not, we will make adjustments at the relay triangle. I am going to stay away from the single shear design Tim had fail on him. I was able to press out the origninal bearing at the front of the arm. I then machined it to fit the FJ bearing so I could use the FJ inner race from the factory relay arm.

The front end is complete as far as mock up is concerned. The key locks the steering head and the steering stops has been modified to ensure the clip-ons don't hit the fairing.

So, once we get this final fitment of the shock & linkage sorted out, it is time to strip it back down for paint on the frame. The engine is painted and ready to install. From them it is the detail work of reassembly, but this is the time things really start moving along.

I think the posts will be more frequent as we are started on the downhill roll.

Randy - RPM

[axiom-r]

Looking really nice Randy!

Would you let us know what shock body, shaft and spring weight you ended up with?  Length center to center?  How much ride height adjustment is available etc...  I am particularly interested in the spring weight and the triangle linkage configuration.  I ended up inverting the stock triangle for a near perfect fit - although no clue what that did to the progressive rate...  I see you got the torrington bearing in there!

When I was mocking up the shock and the remote res clearance issue emerged, I thought about a billet extension block that would mount in the FJ frame and then present a mount for the shock that was an inch or so to the rear.  This would stand the shock more vertically and again impact the progressive rate linkage.  As I recall, the folks at Penske indicated this would be a positive change to help reduce the required spring rate.  The more important outcome to me was that the frame would go uncut at the shock mount. We went with the remote reservoir clip instead to avoid frame contact at the mount.

Nice work on the billet R1 dogbone!

Would love to see the front end and the triple clamp you went with as well as the mods to the steering stop - all critical steps in making the FJR1 happen...

Cannot wait to see this bike on its new wheels!

Cheers!

tim