GSF1200 Wheel Install - 1990 FJ1200

[ANGRYJOE]

As I stated in my previous post...I wanted to see if I could install a GSF1200 rear wheel and brake on my 1990 FJ1200.

After I did the research I found that the GSF and GSXR rear wheel are the same so I knew I could get it to work.

The following picture illustrate the steps I took to get it mounted and operational.

If you are unaware, the size difference is significant.
Here is a side by side comparison.


At this point I will assume that we all know how to pull and install a wheel so I did not take any pictures of that process. Also, the Bandits stock sprocket is way too big and would not work with my chain. The chain and front sprocket on my bike has less than a 1000 miles on it so all I did was order a 38 tooth sprocket. It was 25 dollars shipped.

I did find that only one 20m washer was needed to fill in the gaps.


I installed the washer between the caliper mounting bracket and the swing arm to maintain proper alignment of the caliper and the rotor.



You can use the Bandit rear brake line as well if you are not ready to spring for a steel braided line.
you can see here that it needs some adjustments but will work fine with the FJ master cylinder. Also you can see the space between the tire and swing arm.


you can see the space between the chain and the tire here.


The chain guard mounted allows plenty of clearance.


Now, it is obvious that the Bandits caliper bar will not reach.


the lower bolt on the foot peg is where I wanted to mount the new rod.


here is the view from underneath



I cut the Bandits rod at the weld for the forward mount.


i purchased some3/4" square tube and ground the paint off the rod. Then I inserted the rod into the steel tube. This was a happy accident...and it worked perfectly.

I drilled a hole in the forward end of the steel and ran a 8X1.25 bolt that was long enough to go all the way though the foot peg AND the bar on the other side. I added a lock washer and a nut with loc-tite to secure it in place.

I will weld the bar together at the seam and I will add some plug welds along the length of it. For the time being I drilled a hole and added a bolt to hold it together.



And here it is all mounted up and rolling. It handles extremely well and the back brakes are much better than the stock FJ unit.




If you have any questions let me know and I will answer the best I can.

[FJmonkey]

Looks like your other ride can fly as well....

Good looking work dude.... Clean looking FJ as well....

[ANGRYJOE]

I forgot to mention.....All parts are from a 1997 Suzuki GSF1200. total cost was 150 for the whole wheel assembly and about 15 dollars in steel and hardware.

[FJmonkey]

I forgot to mention.....All parts are from a 1997 Suzuki GSF1200. total cost was 150 for the whole wheel assembly and about 15 dollars in steel and hardware.

GTFO!!! 

[ANGRYJOE]

I forgot to mention.....All parts are from a 1997 Suzuki GSF1200. total cost was 150 for the whole wheel assembly and about 15 dollars in steel and hardware.

GTFO!!! 

Right? Because I am cheap I did not pull the trigger on the 300 dollar GSXR unit from a local salvage yard I found. I would have had to buy a tire as well...so figure another $150 on top of that. I found the Bandit on Craigslist locally. The seller wanted 180,  I offered 150 and a deal was struck....

[FJmonkey]

Right? Because I am cheap I did not pull the trigger on the 300 dollar GSXR unit from a local salvage yard I found. I would have had to buy a tire as well...so figure another $150 on top of that. I found the Bandit on Craigslist locally. The seller wanted 180,  I offered 150 and a deal was struck....

Translation.... Great find and crack like sample to us Moditus junkies...

[fj johnnie]

 That is awesome. Thanks for posting up. A friend of mine has a Suzie Bandit and I have often looked at that back wheel thinking hmmmm, it looks very similar too the Gixxer. Thanks for the info. It will help others widen their search for a rear wheel replacement.

[Bones]

Hey Angry, When you mounted the torque arm to your foot peg bolt, did you add some kind of a bush. The standard gixxer arm has a ball on the end of it so once tightened, is free to move up and down with the suspension.



If not, it might over time wear the bolt out from the constant up and down movement. One way to fix that is to mount the arm to the swing arm where suspension movement wont affect it.

[scotiafj]

  another good write up and source of a 17'' back wheel ,also the suzuki rf's use the same back wheel ,tho the 600 version has a 5  bolt sprocket the 900 has a 6 bolt ,I was gonna use it but couldnt find a 5 bolt sprocket anywhere so sold the wheel and got a gixxer 11 wheel and rear brake setup 

[Arnie]

The 5 bolt sprockets for Suzuki can be had from 41 - 47t.
Any fewer teeth is 'difficult' to find.
The 6 bolt sprockets are easier to find in a greater range.

AngryJoe,

In your 4th pic down you show the brake hose (seemingly) rubbing on the tire.
Have you made some bracket or clamp/guide so this does not occur?

Also, as long as the caliper hanger is mounted next to the wheel, the caliper HAS TO be aligned with the disk.
It doesn't matter how many washers you place between the caliper hanger and the swingarm, the caliper will STILL be in alignment to the disk.
HOWEVER, the chain alignment and the centering of the wheel is much more critical.
Are you sure that the chain is aligned with both sprockets and that their is no "Z" bend in it?

And, as others have pointed out, the forward end of the brake torque arm must be free to rotate.
The easy way would be to use the rose jointed end of the Suzuki bta that you cut off with the steel tubing in the center.

ARnie

[Pat Conlon]

Hard to see in the pictures, but the GSF1200 rim looks to be straight spoke design...true? (vs. the angled spoke design on the Yamaha rims)

Arnie brings up a good point on the spacer washer (against the wheel vs against the swing arm)

Thanks for the write up Joe The sharing of your information with us is much appreciated! 

[ANGRYJOE]

to answer somethings brought up.

you can get the Suzuki sprocket down to 38 and they are no more difficult to find than the other sizes. As I said, I got mine over night from Amazon for less than 30 shipped.

yes, in the picture it is rubbing but if you read the caption I stated it needed some adjustment. Adjustments were made to ensure there were no rubbing. There is a simple bracket I made and mounted on the end of the swing arm to hold the hose in place.

I did state that I mounted the washer on the outside of the caliper bracket. This is because I am a jet engine mechanic and an auto mechanic and this is my first motorcycle. As I was working on the bike I put the washer in various positions to see what was going on. I simply stated that it needs to go on the outside in case someone else who has not had a lot of motorcycle experience could read and see that it goes on the outside to eliminate any unnecessary steps.

For the moment, no there is no ball joint at the end of the rod. I will, in the near future, weld a nut on the end of the rod so I can use a ball joint on the frame side. If I mount it to the swing arm I would have to make a bracket and affix it. As I am all about the KISS method of maintenance and fabrication I will simply use what I have and follow the path of least resistance.

[FJmonkey]

If I mount it to the swing arm I would have to make a bracket and affix it. As I am all about the KISS method of maintenance and fabrication I will simply use what I have and follow the path of least resistance.

I have a few spare brackets I had made that might fit your needs. I did the GSXR under slung caliper but the bracket might also fit other applications.



Might need to drill your own holes...

[ANGRYJOE]

If I mount it to the swing arm I would have to make a bracket and affix it. As I am all about the KISS method of maintenance and fabrication I will simply use what I have and follow the path of least resistance.

I have a few spare brackets I had made that might fit your needs. I did the GSXR under slung caliper but the bracket might also fit other applications.



Might need to drill your own holes...

Did you run the hole all the way thru the swing arm. I could have the fabrication guys at work bend me up a bracket pretty easy but making sure I get the holes even top to bottom....that would require me pulling the awing arm and taking it to work and use the drill press.

[Urban_Legend]

Hey All. just a Noob beginner question. Is there any reason that the brake calliper can not go on the top of the rotor (same as the FJ design) and use the FJ torque bar fixture on the swing arm. ( sorry if the has been asked on other threads)

Do the Suzuki callipers have to be under slung?

Mark