92 Rebuild and Modernization

[axiom-r]

Hello All-

I have been MIA for quite some time - apologies - life can be a real distraction from my FJ addiction..... Jeff- Sorry I missed your emails too. I am sending you an email address that will work better to actually get me!

Amazing progress on your FJR1/R6 conversion.  I am particularly interested in your top triple clamp and the 2" extenders as I have not been very satisfied with the Cycle One Off units. They work - but I want pinch bolts instead of the set screws....

The 2007 R1 swingarm resolves many clearance issues at the top of the shock and subframe because of the "underbracing" vs. "overbracing" design.  On my mod- we did not turn down or shorten any of the machined surface of the swingarm bushings (that the bearings ride on) because that is the "use" area and the thinking was we wanted all of that area for bearing contact.  Instead, we cut the R1 inner bushing spacer exactly in half (sectioned it), removed material from the middle and welded it back together to match the FJ inner bushing length.  Then pressed another set of bushings (one per side about an inch long) inside the R1 piece that had an ID to accept the FJ swingarm axle...  that was it.  The end caps/seals for the swingarm I bought new from Yamaha.

Jeff I have an already modified 2007 swing arm and (I think) a modified inner bushing on the shelf here.  The first swingarm we modified had a gouge on it that was minor and could have been "blacked out" but I found another one that was perfect so we modified a second part....  Perfectionist OCD nit-picking really....   I will check my stash and let you know what might be available...

Regarding the linkage and the triangle - I turned the stock R1 Triangle connection upside down so that the short side connects to the shock and the longer side connects to the dogbone.  This resulted in a "bolt up" solution with good fit.  I did have troubles with the shock and the swingarm well...  The FJ is heavier than the R1 and so the spring is wider- I had to use a special shock set up direct from Penske.  It did not cost more than a typical shock for an FJ but it was custom.  The reservoir would have to have been remote to clear the swingarm and I use a "clip" style mount to create an attached reservoir function.  My spring is 1300 lbs.  If you need them I will get you some more detail on my Penske purchase...  And as Paddy advised - be sure to get a Torrington Bearing kit if and whenever you work on your shock as having that bearing inserted makes pre-tensioning easy and without it I was bending the adjuster tool...

Hoping to make the 2014 WCR Rally this May but can't be sure until its closer to May....  Hope everyone has been well and Happy New Year to all!

tim

[Pat Conlon]

Good to hear from you Tim! Hope to see you in Willits....

[giantkiller]

Tim I still haven't mastered posting pics from my phone. But I do have pictures of my over engineered extensions, in the gallery. I'm working on another idea for the extensions. If it works I'll post here. Sorry about post jack
;

[racerrad8]

Tim I still haven't mastered posting pics from my phone. But I do have pictures of my over engineered extensions, in the gallery. I'm working on another idea for the extensions.

Here is the only one I could find in your gallery.



Randy - RPM

[giantkiller]

Thanks Randy. There's a cut obviously between the pinch bolts.so you don't ;have to worry about water build up. No need for lids. And with the clippons that I made. Once I slid the extensions up were they needed to be. I had adjustable handle bar height.

[axiom-r]

Hey giantkiller-

Jeff had emailed me about his conversion and I popped in to see this thread awhile back.  I did see your extenders at that time and I think I saved the shots as reference.  It would be fantastic not to have to make them so if you can hook me up I am in!  Please keep me posted.   

I think the set you made looks really good- Over engineered?  Not even..... I like proof.

I was going to ask you if they come off easily when loosened?  That is one of the downsides on the press fit extenders - removal is not fun.

It might me in my head but without proper pinch bolts I am suspicious of movement or flex in the front end and that's no way to think while out for a brisk Sunday ride!

Cheers!

tim

[giantkiller]

Yah they are tight. Have to pry a little with a screw driver in the slot. If it works I'm going to have three sets made of the new ones. One for each of my bikes and one for my brothers fj.

[Pat Conlon]

Hey Dan, when the time comes...can you make more than 3 sets?....I'm with Tim.

[giantkiller]

If the machinist thinks it's going to work I'll ask what he wants to make them and I'll let you know.

[axiom-r]

Hey Giant-  I would settle for some dimensions and design details if your guy doesn't want to do them. I can produce locally just thought why bother if someone already has their CNC spinning. 

Pat-  it's good to be back at the surface!  I'm hopeful for Willits!!

Tim

[jscgdunn]

Amazing progress on your FJR1/R6 conversion.  I am particularly interested in your top triple clamp and the 2" extenders as I have not been very satisfied with the Cycle One Off units. They work - but I want pinch bolts instead of the set screws....

On my mod- we did not turn down or shorten any of the machined surface of the swingarm bushings (that the bearings ride on) because that is the "use" area and the thinking was we wanted all of that area for bearing contact.  Instead, we cut the R1 inner bushing spacer exactly in half (sectioned it), removed material from the middle and welded it back together to match the FJ inner bushing length.  Then pressed another set of bushings (one per side about an inch long) inside the R1 piece that had an ID to accept the FJ swingarm axle...  that was it.  The end caps/seals for the swingarm I bought new from Yamaha.

Regarding the linkage and the triangle - I turned the stock R1 Triangle connection upside down so that the short side connects to the shock and the longer side connects to the dogbone.  This resulted in a "bolt up" solution with good fit.  I did have troubles with the shock and the swingarm well...  The FJ is heavier than the R1 and so the spring is wider- I had to use a special shock set up direct from Penske.  It did not cost more than a typical shock for an FJ but it was custom.  The reservoir would have to have been remote to clear the swingarm and I use a "clip" style mount to create an attached reservoir function.  My spring is 1300 lbs.  If you need them I will get you some more detail on my Penske purchase...  And as Paddy advised - be sure to get a Torrington Bearing kit if and whenever you work on your shock as having that bearing inserted makes pre-tensioning easy and without it I was bending the adjuster tool...

Tim and Giant Killer,
Thanks for all the info....I will try to address each item here:
I have 2 inch extenders (Cycle one-off)  They just slide on with no pinch bolts or set screws...just a snug fit.  I do not think the set screws would actually impart much security anyway.  Tim have you noticed any sign of flexing?  Would be a shame to go to the effort of installing a strong front end and then have flexing issues.  I too would be interested in something a bit more robust.

I did get my bushing back with the FJ bushing turned down to fit inside.   The R1 bushing was shortened mostly on the right side as I described, down to the FJ length.  I had to install a thin washer on each side to make up for the thinner dust caps off the R1 and to ensure the FJ bushing has a bearing surface.  In a "do over",  I would shorten the R1 bushing the way I did, but take into account the difference in dust cap thickness to eliminate the washers.  I would also press in the bushings the way Tim did, and probably use the old FJ bushing to make the press in bushings.  The dust caps also had to be narrowed to go back on.  I have it all bolted up and works really good.

I also have the R1 shock and linkage mocked up.  Everything fits really good; as you noticed there is a pretty good lean on the shock.  I will be using a 2012 Honda CBR 1000 shock and I have ordered a 1200 pound spring.  My goal was to modernize the bike as much as possible....but I also am one of those cheapskates.  This shock was a major improvement on the CBR 1000....you can read about it here:

http://www.motorcycle-usa.com/115/11800/Motorcycle-Article/2012-Honda-CBR1000RR-First-Ride.aspx

I was able to pick it up for $100, so I am really hoping it works out.  Sorry no pics...left my phone out at the shop. will get some up in a few days.

[jscgdunn]

A bit more propaganda:

http://rideapart.com/2011/09/the-cbr1000rrs-balance-free-rear-cushion-explained/

[axiom-r]

Hi Jeff- be sure to check the swingarm has a full range of motion with the CB shock in there.  Your higher weighted spring will come in a little wider diameter than the R1/R6 shock as that one is about a 600lb...

When I got my first test spring from Penske (1200lbs) it was too fat for the 2007 R1 swingarm passage....the fixed reservoir fouled on the arm too.  that's how I ended up going custom.  It would be fantastic of the CB spring was the higher weight and the narrow diameter!!  It would make the conversion process that much easier for those who will follow this route after you!

Tim

PS- probably no real flex from the Cycle Oneoff's but I would feel better bolting the extenders on - as agreed the set screw is worthless...

[Pat Conlon]

(quick hijack) Hey Tim, I was thinking of you when this was posted: http://www.fjowners.com/index.php?topic=10645.msg105048#msg105048

[jscgdunn]

Thanks Tim,
I am hoping there will be enough room for the spring...there is good clearance for the R1 shock so here's hoping.

The Honda reservoir may cause issues with the battery box....but I do not think it will interfere with the swingarm: