FZ1/FJ Forks and Swingarm Conversion by Frank Moore
I originally intended to modify my 86 FJ1200 using the tried and true YZF600 mods but was having trouble locating all the parts necessary to to do the conversion. One day I decided to visit my local bike salvage yard and actually bumped into a wrecked 2001 yamaha FZ1. Looking closely at the forks and swingarm I decided to attempt grafting them onto my bike.
Front Forks - " The more things change the more they stay the same" This is very simple process as all you need to do is mill 2mm from each of the four holes in the stock triple clamps and 2mm out of each handlebar. The stock parts are 41mm and the FZ1 forks are 43mm
comparison photos of the FZ1 and stock FJ triple clamps
(http://i47.photobucket.com/albums/f198/Racerman27410/FZ1%20mods/yoke1.jpg)
(http://i47.photobucket.com/albums/f198/Racerman27410/FZ1%20mods/yoke2.jpg)
the stock FJ triple (left) is actually beefier than the FZ1 unit so i used it ;D
Voila`( yes its that easy) the front end just slips right in. Connect and bleed the brakes you are ready to ride ( almost ) here is the only downside to this conversion - you lose the speedo drive from the front wheel. I took care of this problem by installing an electronic unit from Acewell with the pickup on the front left brake caliper.
(http://i47.photobucket.com/albums/f198/Racerman27410/IMG_0738.jpg)
this serves as Speedometer,tach,fuel gauge,oil temp gauge,voltmeter,dual tripmeters,max speed average riding time etc etc ;D
. One bonus of using the FZ1 front end is that the FZ1 top plate fits right onto the FJ allowing the use of Superbike style handlebars in any rise and bend you prefer. The stock FJ ignition switch fits right on to the FZ1 top plate even retaining the steering lock! I call this my touring setup and it takes less than an hour to swap from my stock bars to this more upright riding position.
FZ1 top plate
(http://i47.photobucket.com/albums/f198/Racerman27410/FZ1%20mods/yoke3.jpg)
Front end complete
(http://i47.photobucket.com/albums/f198/Racerman27410/FZ1%20mods/finishfrontright.jpg)
(http://i47.photobucket.com/albums/f198/Racerman27410/FZ1%20mods/finishleftfront.jpg)
Swingarm and rear wheel - First I used the method Barry described in his Thunderace swingarm conversion, pressing in the bearings further into the FZ1 swingarm using a bolt, nut and flat washers to ride against the bearings. I used the stock FJ inner bushing to guide me as to how far to go ( approx 2.5mm off each side ). After pressing in the bearings I cut off the excess material with my all singing, all dancing Dremal tool. For assembly I re-used the stock FJ inner bushing, thrust washers and end caps along with the stock pivot bolt. No need to worry about centering the wheel in the swingarm as its aready done for you. Torque to spec.
Note :- This setup will not work with the stock exhaust as the meaty 5.5 inch rear wheel and swingarm are too wide and will hit the silencers. With my Supertrapp exhaust I simply rotated the S-pipe and put the mount on the outside of the passenger peg mount instead of the inside.
Mounting the swingarm was the easy part and the rest would have been even easier had I owned a later model FJ with the dogbone style shock linkage. As it was my 86 shock had an eye mount both top and bottom. My new setup was going to require a clevis stlye lower mount like the 89 and up FJ`s have . I wound up sourcing a shock and lower pivot from an 89 FJ. The dogbones I used are handmade adjustable units but as decribed elsewhere on this site its easy enough to make your own using flat plate.
One other problem concerned the rear brake light switch which was interfering with the swingarm during its stroke. I used a hydraulic banjo bolt brake pressure switch from Four strokes only -
Next we approach the drive chain. Being that the wheel is wider I sourced an offset countershaft sprocket originally for a Honda VF1000R (86-87 model ) the sprocket has an offset on both sides. I ground one side of the sprocket offset flush and fitted the sprocket onto the bike with the factory offset to the inside facing the engine. Stepping it out just the right amount.
This left just enough room to get the locking tab and nut on the shaft and it all lined up perfectly with the new rear sprocket. The FZ1 wheel comes with a 44 tooth sprocket and with my use of a 18 tooth countershaft sprocket managed to keep gearing basically the same as the stock 17/41. Remember the rule one tooth on the front = three on the rear.
rear end complete
(http://i47.photobucket.com/albums/f198/Racerman27410/FZ1%20mods/finishleftrear.jpg)
(http://i47.photobucket.com/albums/f198/Racerman27410/FZ1%20mods/finishrightrear.jpg)
There you have it; this conversion netted me an impressive 20.1 lb reduction in unsprung weight and improved handling in spite of lengthening the bikes wheelbase by 1.5 inches. By raising the rear ride height I altered rake from the stock 27.5 to 24.5 and trail from 5.5 to 3.5 inches. Handling is very precise now with great turn in and feedback from the front wheel thankfully the tendancy to stand up under braking is MIA. and I can shop for tires to my hearts content.
The brakes are very progressive especially the rear which combined with the stock FJ master cylinder resists locking and has better feel than any rear brake I`ve ever used. The front brakes are equally impressive with the FZ1 master cylinder.They give good feel and serious power. Enough to lift the rear wheel of the old girl and put me on the windscreen ;D
My favorite has to be the modern meaty 180/55-17 rear tire. It really brings the bikes proportions more in line with modern motorcycles as well as offering greater tire selection and traction for the torquey grunt of the FJ. I wanted to try and keep the bike as stock looking as possible,with modern suspension, brakes and wheels. 8)
(http://i47.photobucket.com/albums/f198/Racerman27410/FrankBike.jpg)
sweet! thanks for the write up and the great pics
Ogmudbone
Frank, very nice ride .
Amazing Frank...... seeing what you have done makes me want to shake out the cobwebs and wake up the mod bug.....
Quote from: karstenp on February 12, 2009, 06:59:56 PM
Amazing Frank...... seeing what you have done makes me want to shake out the cobwebs and wake up the mod bug.....
it's easy..... just get some parts and then make them fit ;D
KOokaloo!
Frank
Frankie baby,you are an inspiration!!!That is a sweet little m/cycle.And that was probably the easiest and best explanation for those mods that I have heard so far.Thanks mate,Dave. :)
Quote from: Davetammy on February 12, 2009, 09:19:15 PM
Frankie baby,you are an inspiration!!!That is a sweet little m/cycle.And that was probably the easiest and best explanation for those mods that I have heard so far.Thanks mate,Dave. :)
It also works pretty good on a late model,,,
(http://i662.photobucket.com/albums/uu349/Yamifj1200/Picture024001.jpg)
Eric M
Frank your next mod is a 02 or later R1 wheel in your FZ1 swing arm (It fits with not much modding) Look in the FZ1 web site it's all there.
Kim ;D
Dave, as EricM said........you will see it in a couple of weeks on mine.
Harvy
Sweet Harvy!
hi Frank
got to ask did you get things like the fuel gauge/rev counter to work ok???
any "big" problems with the clocks???
Regards Mark
Quote from: markfjer on March 08, 2009, 01:50:45 PM
hi Frank
got to ask did you get things like the fuel gauge/rev counter to work ok???
any "big" problems with the clocks???
Regards Mark
Mark,
yes you do lose the speedo drive with the FZ1 conversion but all the other gauges work just as factory.... i took care of the speedometer situation by installing one of these very nice units...
(http://i47.photobucket.com/albums/f198/Racerman27410/IMG_0738.jpg)
it has a tach, oil temp, fuel gauge,voltmeter, dual trip meters, average riding time, average riding speed and max speed
KOokaloo!
Frank
cheers frank
yep seen u had installed said item (and the reasons y)
just want to confirm that revs/gas etc was all ok as to me they seemed where u may have had problems
also the alignment of the speedo, any big problems??
cheers mark
....... Sweet!!!!
Quote from: markfjer on March 08, 2009, 03:51:31 PM
cheers frank
yep seen u had installed said item (and the reasons y)
just want to confirm that revs/gas etc was all ok as to me they seemed where u may have had problems
also the alignment of the speedo, any big problems??
cheers mark
Mark,
rev counter and gas gauge work just fine with the FZ1 mod...... nothing on the front or rear ends have anything to do with their operation...the front end only affects the speedometer as there is no place to connect the drive cable @ the wheel..... not sure what you mean by "the alignment of the speedo"
Kookaloo! :wacko1:
Frank/Eric, do you have stock internals in the legs?...... I'm considering having mine done done with Racetech springs and valves b4 I have them shipped to Aus......your thoughts?
Harvy
Harvey,
Depending on what you decide to do, I can install the RT components for you. I normally get $100USD + parts to to go through a set of cartridge forks including installing the Race Tech valving. (they do most of the thinking, so its all labor at my end)
Quote from: Harvy on October 20, 2009, 08:53:36 PM
Frank/Eric, do you have stock internals in the legs?...... I'm considering having mine done done with Racetech springs and valves b4 I have them shipped to Aus......your thoughts?
Harvy
Harvy,
I have the traxxion axxion valves in my forks.Max didnt have much good to say about the stock FZ1 valves (which are not rebuildable/tuneable) he makes a nice adapter so other valves can be fit.... does race tech also have these adapters? you pretty much have to have them if you plan on revalving the forks.
that being said the stock FZ1 forks were still worlds better than the damper rod stock forks (emulator equipped)
KOokaloo!
Frank
Bill, the parts are currently occupying "very little space" in Garth's garage.
I will look into what I need but I think this for starters:
Type 1 Gold Valve Kit – Standard Type 1 Compression Kit FMGV S2047C $399
I assume these are shipped adjusted for rider weight/intended use?
and
Fork Spring Series (pair) FRSP S3732 $109.99
Not sure what spring rate I would require, as the website calculator is calibrated on FZ1 dryweight rather than FJ.
I think around either .85 or .9 given that my OEMs with Emulators and .95 do a great job.....
AND Frank says these are far better forks in OEM configuation than mine even with the upgrade.
Thanks for the offer mate.....I'll let you know.......any comments on the above?
I would probably also eventually get an FZ1 Superbrace, as I am sold on their benefits.
Cheers
Harvy
With the weight of the FJ go with .95 if not 1.0. I have 1.0 springs in my FZ1 and I come in at about 220Lbs. and the springs are just a touch light. :good:
Quote from: tqmx1 on October 20, 2009, 11:57:05 PM
With the weight of the FJ go with .95 if not 1.0. I have 1.0 springs in my FZ1 and I come in at about 220Lbs. and the springs are just a touch light. :good:
A touch light you say...... well that sounds like .95 - 1.0 would be just right for me.......I'm a lightweight at 63Kg.
Cheers
Harvy
Quote from: Harvy on October 21, 2009, 01:32:29 AM
Quote from: tqmx1 on October 20, 2009, 11:57:05 PM
With the weight of the FJ go with .95 if not 1.0. I have 1.0 springs in my FZ1 and I come in at about 220Lbs. and the springs are just a touch light. :good:
A touch light you say...... well that sounds like .95 - 1.0 would be just right for me.......I'm a lightweight at 63Kg.
Cheers
Harvy
yeah but the FJ is not a lightweight so i would go for the 1.0kg springs....and double make sure the race tech valves come with the adapter for the FZ1 ....
KOokaloo!
Frank
Harvy,
I have not seen the cartridges, but race tech is very good about getting the proper information to certified installers (I am one, since '92 or so) If fine tuning is necessary I am sure it wont be an issue. 1.0KG/mm springs would be the correct rate for your weight on an FJ.
Frank, what mods are necessary for the wheel to fit in the FZ1 forks, assuming you are using the FJ triples bored out to work?
Quote from: Harvy on October 20, 2009, 11:20:49 PM
Bill, the parts are currently occupying "very little space" in Garth's garage.
I will look into what I need but I think this for starters:
Type 1 Gold Valve Kit – Standard Type 1 Compression Kit FMGV S2047C $399
I assume these are shipped adjusted for rider weight/intended use?
and
Fork Spring Series (pair) FRSP S3732 $109.99
Not sure what spring rate I would require, as the website calculator is calibrated on FZ1 dryweight rather than FJ.
I think around either .85 or .9 given that my OEMs with Emulators and .95 do a great job.....
AND Frank says these are far better forks in OEM configuation than mine even with the upgrade.
Thanks for the offer mate.....I'll let you know.......any comments on the above?
I would probably also eventually get an FZ1 Superbrace, as I am sold on their benefits.
Cheers
Harvy
Quote from: the fan on October 21, 2009, 04:17:02 PM
Frank, what mods are necessary for the wheel to fit in the FZ1 forks, assuming you are using the FJ triples bored out to work?
Quote from: Harvy on October 20, 2009, 11:20:49 PM
Bill, The wheel will have to be FZ1 also I believe......I currently have a 3.5 '88 Genesis front wheel, but would like to use the FZ1 front wheel to match the one on the back ...... straight spokes as opposed to the angled FJ / Genesis wheels.
Do you know the answer to Franks question regarding the valve adapter?
Cheers
Harvy
I don't but will give RT a call tomorrow.
scratch that. Louie (tech manager at RT) was in the office and tells me that everything needed to install the valves in the FZ1 fork is included. (except the holder tool, which I have, and is easily replicated... He claims that it is pretty much plug and play and that we can easily adjust the valve stack to accommodate the additional weight.
Quote from: the fan on October 21, 2009, 06:36:28 PM
I don't but will give RT a call tomorrow.
scratch that. Louie (tech manager at RT) was in the office and tells me that everything needed to install the valves in the FZ1 fork is included. (except the holder tool, which I have, and is easily replicated... He claims that it is pretty much plug and play and that we can easily adjust the valve stack to accommodate the additional weight.
right on.... they (R/T) would have to supply everything since the stock FZ1 compression and rebound valves are riveted to the valve holder.... Max took a look at them and said they were just one step up from damper rod orifices.... of course he was trying to make the sale (and did) but to go along with his claims there was a huge difference in the fork action after we installed the axxion valves.
Kookaloo!
Quote from: the fan on October 21, 2009, 04:17:02 PM
Frank, what mods are necessary for the wheel to fit in the FZ1 forks, assuming you are using the FJ triples bored out to work?
Bill,
I'm using the complete FZ1 front end.... no mods necessary except boring the stock FJ triples and handlebar mounts out an extra 2mm and fitting an electronic speedometer.
i'm all about the plug and play :biggrin:
good deal. didn't realize that the forks were on the same center lines. That makes things a lot easier.
Thanks.
First post, I am rebuilding a 1991 3xw here in the UK's lake district, looking to fit modern tyres and brakes, whick means ditching the abs stuff, no big deal as it does'nt work anyhow, am swapping the front forks for Thundercat items and getting rid of the steel rear swingarm, this is it currently
(http://i305.photobucket.com/albums/nn208/hrhpenfold/FJ1200/fj%20rebuild/DSCF3074.jpg)
How does the use of the Fz1 swingarm effect the chain length, I assume the stock shock, fits quite easy, unlike the thunderace one that needs machining for clearence?
Ian,
Interesting project – keep up the progress reports. I'm often down from Glasgow for a run round the Lake District. My favourite route is Carlisle, Silloth, down the coast to Eskdale then over the Hardknott, Wrynose & Kirkstone passes to Penrith for a visit to "The Little Chippie" (fish & chip shop) I suppose there must still be a lot of disruption near you due to the recent flooding and loss of bridges.
Stuart
Quote from: flyingbanana on December 19, 2009, 05:53:16 AM
How does the use of the Fz1 swingarm effect the chain length, I assume the stock shock, fits quite easy, unlike the thunderace one that needs machining for clearence?
no worries on the shock clearing. Depending on the gearing you plan to run the chain might be a couple of links longer than stock.....i never really counted the links to be honest...... i usually just buy the standard 120 link chain and then cut of what's not necessary.
i love a good project! :good2:
KOokaloo!
Frank