92 Rebuild and Modernization

[movenon]

Thanks for the information Jeff. It looks like a GSXR wheel could squeeze in there with some spacer work. Take about 6mm (.23 inch) off each side if I read it correctly.

Your picture of the rear sprocket shows the chain tracking outboard a little by 1 or 2 "eyeball" mm"s. I am looking at the rear sprocket teeth set in the chain. If that's the case you could reduce that front sprocket offset a little ? I used a Motion Pro chain alignment guide and found it helpful. Down here they are a 16.00 item.

http://www.motorcycle-superstore.com/4876/i/motion-pro-chain-alignment-tool?SiteID=Google_PLA995&WT.mc_ID=10012&esvt=0-GOUSC&esvadt=9-0-3886819-1&esvaid=30548&device=c&matchtype=&network=g&gclid=COCly5OGprsCFYlhfgodL2AAww

Motion Pro: How-To Video: Chain Alignment Tool 08-0048

George

[Dan Filetti]

Chain Alignment

Not too scientific, but the chain looks aligned with this offiset

I am convinced that this is one of the many application that the proliferation of the many, and easy to find site lasers could really help with.  Yup, by site it sure does look straight and true, bu wouldn't it be great to KNOW it?  I'd bet a dollar you already own a laser that could be re-tasked for just this point.  If not I saw some at 5 Below the other day for well, less than $5....

Dan

[racerrad8]

Loosened off to align the chain.  Measurement of the offset required was 6MM

Jeff,

I stock a PBI 18T sprocket with an advertise offset of 1/4" which is about 6.27mm.



I do not have it listed on the website, I stock on for these types of application.

Let me know if I can help, Randy - RPM

[jscgdunn]

Thanks Dan and George,
I too saw the offset of the chain on the sprocket this AM when I put the pic up...never really noticed it before.  Makes me think that if the chain is centered on the sprocket, it must be pretty close to straight.  Will look at it this week end.  Next time I am at home depot will check for a small magnetic laser level.  The chain alignment tool looks like it would take a lot of guess work out of trying to use the alignment marks on the swingarm.

Here are the other pics of the spacer

[jscgdunn]

Loosened off to align the chain.  Measurement of the offset required was 6MM

Jeff,

I stock a PBI 18T sprocket with an advertise offset of 1/4" which is about 6.27mm.



I do not have it listed on the website, I stock on for these types of application.

Let me know if I can help, Randy - RPM

Thanks Randy....there certainly will be help required....but I think I have a Honda VF1000 sprocket coming....should have checked first    

[jscgdunn]

Here is another shot of the FZ1 top triple.  You can see the black 2 inch extensions. I have heard there are three inch extensions, but R1 fork tube is tapered where the bottom triple clamps, and two inches seems to be at the top of the taper, so I am not sure how the three inch extension would work.

The FJ ignition switch can be made to fit.  I used 4 3/8 nuts as spacers and longer bolts.  I also had to drill out the mounting holes on the switch because the FZ1 holes are larger and spaced further apart.



Here it is mounted.  The lock does line up...but I actually never have used the lock so not too concerned.  Looks like I am going to have to find a less rusty nut...looks out of place with the new hardware.



The steering stops will need addressing.  Turning radius is not as tight as the FJ...Tim (ie Axiom) says it is not an issue.

[racerrad8]

Thanks Randy....there certainly will be help required....but I think I have a Honda VF1000 sprocket coming....should have checked first  

I suspect so, you are going to need the XJR sprocket cover, shift rod & push rod as well as I believe the stock cover will not provide enough clearance.

Randy - RPM

[movenon]

I eye balled mine and thought it was pretty good until I used the tool.  Its is a simple tool but works great. Essentally just a steel rod that you can mount or clamp parallel to the rear sprocket.

[fj johnnie]

 I agree with Randy. When using an offset sprocket the cover will interfere with the sprocket. The sprocket cover will rub even with the metal bracket/ sound deadener removed from inside. Consequently the one bolt from the clutch slave that threads into the cover will be ruined, and will be shortened enough that the bolt will no longer hold. I know this because I purchased an already modded bike....... Randy has all the parts you need. When removing the shift shaft do the clutch mod he recommends also. You will be happy you did. No clutch slip is the consequence. Awesome to read about your bike. I am currently re-doing an 86 and have a very nice 84 with 25,000 orig k's waiting for a full blown moditis attack!!!!

[fj1289]

Loosened off to align the chain.  Measurement of the offset required was 6MM

Jeff,

I stock a PBI 18T sprocket with an advertise offset of 1/4" which is about 6.27mm.



I do not have it listed on the website, I stock on for these types of application.

Let me know if I can help, Randy - RPM

Randy, do you carry these in 17 teeth as well?  What's the cost?  Would prefer to go thru you than Trac again...

Thanks!

[racerrad8]

Randy, do you carry these in 17 teeth as well?  What's the cost?  Would prefer to go thru you than Trac again...

Thanks!

Chris, I can get them, but I do not have them on the shelf. I order one of these for someone and I thought I better get two for the next guy that wants one, so it is sitting on the shelf.

Let me know if you need something and I can order it.

Randy - RPM

[jscgdunn]

The Motor
I bought this motor from Rick Tae who advertised it on this forum.  As I recall it has around 15,000 KMs on it.  It came from '92 he crashed.  Long story;  Rick lives on Vancouver Island and was "getting out of FJs" so I bought everything he had left from the crashed bike. All of the pieces are in really good shape and included complete wiring harness etc.  I will be putting these parts on this bike. 

Last winter Rick was able to get the collection to a friend of mine in Vancouver.  So then I had to figure out a way to get the parts to Calgary. I ended up hiring a horse transporter who picked up everything.  There was the motor and three cardboard boxes, which she put in the tack room of the trailer...along with a few bags of sawdust used for bedding the horses.  At any rate I ended up three boxes filled with liberal amounts of sawdust and FJ parts.  Sorting it out was kind of like a treasure hunt.  Anyway, here it is in the frame.



Because I had everything apart, I put the motor on my table, slipped the lower subframes under the motor, then draped the main frame over the motor.  After a few minutes of lining things up, the motor was bolted to the frame.  I then used the skid steer to pick it up and put the forks on and drop the centre stand.

In and out
Rick had already sold the carbs form the motor;  I was able to find a fuel pump set from a guy in Manitoba.  I am not sure if the had ever been apart as  the screws appeared unmolested.  By the way those are JIS standard screwdrivers...highly recommended to reduce the aforementioned molestation.
Here they are cleaned up.


I plan on running unipods and a Supertrapp 4 into 1.  Jetting advice is most welcome.  Typical riding elevation is 3000 to 4000 feet.

[aviationfred]

Jeff,

The 2003 swing arm looks awesome. The 2008 swing arm looks good too. I am following this post with great interest as a possibility to attempt the swing arm mod on my 89'. I did look on eBay for R6 swing arms......WOW, they are dirt cheap.

Fred

[jscgdunn]

Thanks Fred,  Yes the parts are very reasonable and very low mileage....still some sorting out to do for sure.

Jeff
PS: My 89 project (with your lower frame rails) is still in the works....Basically putting it together from all the parts I 've collected over the years. 

[rktmanfj]

Loving this thread... especially all the pics and fine details.