FJ1200 with a bit of Exup ru and a bit of R1 big bang

[Russfjr1]

Well this is my project and it should be on the road this summer (famous last words)
So I bought this FJ a little while ago a nice running ABS model I then acquired the big heavy duty (but light) under-braced swinging arm off a late R1, two R1 rear wheels one 3 spoke the other 5 then come the Exup ru usd front end complete with wheel 6 pot calipers top, bottom yokes and speedo drive. I also have another r1 front 3 spoke wheel (after a 5 spoke).  First thing was off with all the plastic bit's and start the plastic welding, just a few age related cracks on most of the bolt holes, now as much as I like the looks of the FJ I do like twin headlamps so while the plastic welder is out .... found a cbr600rr top fairing on ebay like new had to have it, then again on ebay got a new twin headlamp for the cbr600rr (1995). Loads of chopping welding grinding more chopping and it's not looking bad IMO (will ad photos soon). All plastics done and in two pack primer. Swinging arm mmmmm deep thought, measuring more thinking measuring then cut off 14mm off the right side then using a combination of the R1 inner sleeve and the FJ swing arm pin / bolt it fitted with space both sides for dust / dirt caps. I made these on the lathe out of aluminium complete with internal grooves for "o" rings. Rear shock, standard FJ  and perfect central fit in the hole of the arm the triangles however are still being made and thought about. The front end was removed offered up the Exup front it fitted with no big problems just had to mod the turn stops on the bottom yoke and take about 15mm off the pins the ignition switch bolts to, drill it tap it job done even the steering lock works .... happy days     Next post will be with more info and photos.  Russ   
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[movenon]

Pictures Russ ! 
George

[Country Joe]

Well this is my project and it should be on the road this summer (famous last words)
So I bought this FJ a little while ago a nice running ABS model I then acquired the big heavy duty (but light) under-braced swinging arm off a late R1, two R1 rear wheels one 3 spoke the other 5 then come the Exup ru usd front end complete with wheel 6 pot calipers top, bottom yokes and speedo drive. I also have another r1 front 3 spoke wheel (after a 5 spoke).  First thing was off with all the plastic bit's and start the plastic welding, just a few age related cracks on most of the bolt holes, now as much as I like the looks of the FJ I do like twin headlamps so while the plastic welder is out .... found a cbr600rr top fairing on ebay like new had to have it, then again on ebay got a new twin headlamp for the cbr600rr (1995). Loads of chopping welding grinding more chopping and it's not looking bad IMO (will ad photos soon). All plastics done and in two pack primer. Swinging arm mmmmm deep thought, measuring more thinking measuring then cut off 14mm off the right side then using a combination of the R1 inner sleeve and the FJ swing arm pin / bolt it fitted with space both sides for dust / dirt caps. I made these on the lathe out of aluminium complete with internal grooves for "o" rings. Rear shock, standard FJ  and perfect central fit in the hole of the arm the triangles however are still being made and thought about. The front end was removed offered up the Exup front it fitted with no big problems just had to mod the turn stops on the bottom yoke and take about 15mm off the pins the ignition switch bolts to, drill it tap it job done even the steering lock works .... happy days     Next post will be with more info and photos.  Russ   
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Welcome, ya mad modder!!!

[jscgdunn]

This might be helpful....I have done the same but I see my picture management is not good.


http://www.fjowners.com/index.php?topic=3148.0

[Russfjr1]

Modified fairing to twin headlight, new headlight from cbr600rr 2005

[Russfjr1]

If I get enough interest I know someone who can make a mould from this to produce others! The good thing with that would be a uniform interior and possibly lighter in carbon

[Russfjr1]

Front end, had to drill the lugs for the turn stops added m6 screws (flat head to hit the stop) now adjustable turn stops  the ignition posts had to be cut down but having done this simple mod everything works including steering lock just as it should. The complete front end is from a Exup RU 1000 with some really nice calipers, 12 pots of stopping power! That will come in very handy trying to stop from the dizzy heights of 30mph 

[Russfjr1]

Handle bars !!!! made these bar holder oners from billet aluminium aircraft grade of course  . As for the bars the item you can see (just) in the photo is only for mock up I think the bars that will be used might be flat with a bit of pull back.

[Russfjr1]

These two help with making things   

[Pat Conlon]

Ok Russ, you have me hooked..... I like what your vision and what you have done. I admire your skills.

You are a interesting fellow.

[Country Joe]

If I get enough interest I know someone who can make a mould from this to produce others! The good thing with that would be a uniform interior and possibly lighter in carbon

[Pat Conlon]

I see Russ has a late model ABS bike, I wonder if that fairing could be made to fit the early FJ's?

I really like the larger air scoops for cooling the top end vs. the small scoops we have on our early bikes.

Yea, I'm gonna follow this build closely...

[Russfjr1]

Thanks for the comments much appreciated when others like things I have done    Did a bit more to the rear end today, it's totally amazing how little work is actually needed to get things to line up like the chain and getting the wheel central to the bike. With the chain ... simple, made a 3mm spacer for the front sprocket, you can still use the original nut just turn it around so the recess part is to the outside. I will use a bit of thread lock on this as well as the lock tab. The rear end just needed 3mm off the outer spacer from the sprocket side that put the chain to within a couple of mm, I could and will if needed turn the sprocket around to gain a bit more from the recess on the sprocket and because of the s arm having some taken off it to fit the frame the wheel is within 1mm of centre. So not a bad day and I get to keep my 190 tyre.  Just need to make a small spacer caliper side and make the rectangular lug bigger by about 5mm in depth (it stands out on the bracket and locates in the s arm in place of a torque arm)     

[Russfjr1]

I see Russ has a late model ABS bike, I wonder if that fairing could be made to fit the early FJ's?

I really like the larger air scoops for cooling the top end vs. the small scoops we have on our early bikes.

Yea, I'm gonna follow this build closely...

Anything can be made to fit with a little thought ..... and a big hammer  

[Russfjr1]

just a few photos of the rear, main bit going on next is the triangle (last photo). The shock has good travel just need to get the measurements correct to get a nice ride from the rear, have made the adjustable dog bone now trying to figure a way to produce an adjustable triangle but retain strength and keep the dimensions within reason.... might have to use titanium or something to make it compact but strong.