Parts missing/broken in forks fj1100

[mikefootusa]

Hey all, picked up an '85 last month and figured since I had the front wheel off for a new tire I may as well do front wheel bearings and seals, fork seals and wipers at the same time.  Working for a Yamaha Golf Car dealer as a Parts Counterman does have some advantages...lol...and I was able to get most of the parts directly from Yamaha at dealer cost.

When I got into the forks I found bent/broken/missing wave washers (#26) and missing washer (#25).  Unfortunately these parts are no longer available and I can't seem to find and specs on them anywhere.  The wave washers I may have found some that may work (kingpin washers from a Club Car)  But I really need to know what the specs are for these two parts...If anyone happens to have a set of forks apart that they could measure.

Also there is a screw (referred to as a "Damper rod stopper screw" in the manual) that doesn't seem to show up on the parts fische.  It is a small (m3?) about an inch long with threads only on the head end and a smooth pin that is designed to hold the damper rod I assume.  Apparently one PO has slammed the seals out without removing them and they are sheared/bent.  Unfortunately one PO has also used channel locks on the fork sliders...I have filed off the high spots and filled in the dings with some JB Weld...will clean up with some emery and 3M before I put it back together.

Will also try to post up some pics of these parts.

Thanx
Mike

[Dads_FJ]

Where do you reside Mike?  I might have parts for the 84/85, but are you sure you don't want to upgrade to the >89 setup?

[mikefootusa]

Thanx for the reply John.  I edited my profile.  I guess I should do some more research on the fork upgrade.  Thank God for forums.

[Dads_FJ]

Thanx for the reply John.  I edited my profile.  I guess I should do some more research on the fork upgrade.  Thank God for forums.

1989 and up FJ1200 bikes came with a 17" front wheel which also offers the benefit of upgrading brakes by simply bolting on calipers from the R6/R1/FZ1 series bikes.  Lost of parts available from this site as well as ebay. 

http://www.fjowners.com/index.php?topic=10417.msg100916;topicseen#msg100916

[movenon]

Hey all, picked up an '85 last month and figured since I had the front wheel off for a new tire I may as well do front wheel bearings and seals, fork seals and wipers at the same time.  Working for a Yamaha Golf Car dealer as a Parts Counterman does have some advantages...lol...and I was able to get most of the parts directly from Yamaha at dealer cost.

When I got into the forks I found bent/broken/missing wave washers (#26) and missing washer (#25).  Unfortunately these parts are no longer available and I can't seem to find and specs on them anywhere.  The wave washers I may have found some that may work (kingpin washers from a Club Car)  But I really need to know what the specs are for these two parts...If anyone happens to have a set of forks apart that they could measure.

Also there is a screw (referred to as a "Damper rod stopper screw" in the manual) that doesn't seem to show up on the parts fische.  It is a small (m3?) about an inch long with threads only on the head end and a smooth pin that is designed to hold the damper rod I assume.  Apparently one PO has slammed the seals out without removing them and they are sheared/bent.  Unfortunately one PO has also used channel locks on the fork sliders...I have filed off the high spots and filled in the dings with some JB Weld...will clean up with some emery and 3M before I put it back together.

Will also try to post up some pics of these parts.

Thanx
Mike

Part 25 and 26 I think are there because of the anti dive system ? If the system is not in use and blocked off (some have been) then you can probably delete those washers....? Somebody with anti dive can chip in here. Mine submerges just fine   .

The screw you are referring to on the bottom is a locating pin for the dampener part 10-51. They are still available through Yamaha I think. But you could go up to Ace hardware and buy a SS screw to replace them. The screws will be a little long and have threads all the way to the end. Trim the screw to length and you can file / sand or grind the threads down a bit on the ends so the dampener rod will just go over it. Or as I did, open up the slot in the rod with a file so it just slides over the screw. Make sure the screw doesn't protrude into the dampener tube so far that the 10 mm allen bolt will be blocked on reassembly. Don't forget the little O rings.. My dampener locator screws were JIS and I bought SS allen heads (4mm ??) to replace them with. Did the same for the fluid drain screws.
George

[racerrad8]

What measurement do you want/need for the washers, I will try and dig some up.

The screws are still available from Yamaha; 1TX-23181-00-00

Those screws are to keep the damper rod proper indexed and they get screwed up all the time by people not properly holding the damper rod before torquing the bottom bolt.

If you convert over the RPM fork valves the damper rod no longer is adjustable and they are not required to be indexed and you can eliminate those long screws.

Randy - RPM

[mikefootusa]

I guess the real question I have here is...what can I do for the simplest, most cost effective solution to this problem.  Can I effectively just eliminate the AD devices by removing the extra hose and putting a shorter banjo bolt in?  Where do I need to drill holes above the taper and what size?  Are the missing wave washers and flat washer a problem?  I got some new 3M screws to use as alignment pins...just need to file them down a bit at the end.

I also read that plain 10W40 can be used (rider=230 lbs) or is straight 15W better for fork oil?  Don't have the $$$ for cartridges...guess that's why I'm riding '80's motorcycles.

Thanx
Mike

[FJmonkey]

For the  AD units, remove the extra hoses, use shorter banjo bolts, remove top half of the AD unit (toss it), flip the bottom half over for cosmetics.

[mikefootusa]

For the  AD units, remove the extra hoses, use shorter banjo bolts, remove top half of the AD unit (toss it), flip the bottom half over for cosmetics.

Thanx FJmonkey, I thought I'd have to buy those over-priced block-off plates I've seen.

Ready to put this back together and still wondering about the missing washers and if I should drill into the lower tapered cylinder tube.

[FJmonkey]

For the  AD units, remove the extra hoses, use shorter banjo bolts, remove top half of the AD unit (toss it), flip the bottom half over for cosmetics.

Thanx FJmonkey, I thought I'd have to buy those over-priced block-off plates I've seen.

Ready to put this back together and still wondering about the missing washers and if I should drill into the lower tapered cylinder tube.

No problem, I see that others have done this and just passed it along. I skipped this part and ditched my 86 forks 89 forks and put in the RPM valves. I still strongly recommend putting the RPM valves in. The handling difference is like fixing a safety issue. Your front tire will spend way more time in contact with the road. The small bumps will no longer be felt and your attention will stay on the road in front of you, not on the feed back from minor surface conditions. However, you will notice how crappy your rear shock is after the upgrade. So, do this mod as soon as you can. Ride safe.

[mikefootusa]

Getting ready to put these forks back together and still wondering if I can go without the 2 wave washers and the 1 flat washer #'s 25 and 26 in the fische above.  I intend to turn the AD caps upside down and eliminate the brake hoses...but still at a loss as to improve the suspension short of installing the RPM valves (I do hope to do that down the road) but just want to get this thing running safely so I can determine what other work this thing needs. 

Rebuilding the front calipers this weekend...what a piss poor design...wish I had done more research on this model before jumping...but the price was pretty good.

[jamesearthdrum]

Hey Mark,
Will the parts he's missing be in the '86 forks I have? If so, Mike PM me an address and I will send them to you.

james

[FJmonkey]

Hey Mark,
Will the parts he's missing be in the '86 forks I have? If so, Mike PM me an address and I will send them to you.

james

I can't say, if the parts are in your forks then yes.

[mikefootusa]

Hey Mark,
Will the parts he's missing be in the '86 forks I have? If so, Mike PM me an address and I will send them to you.

james

Still waiting James.

[yampug]

completely off topic but is that your first and last name as your user name mike? as my dad's name is also mike foot. only other mike foot i know of is michael foot the english politician.