Bringing the old girl into the new millennia

[Bozo]

Installing a new ( old stock) blinker light switch set and tidying up some wiring while it's apart.

Hey Mark, I'm looking for one of those for my '84. I like the 'flash to pass' feature on the non USA version.

Do you know if you can find any more of those switch assemblies?

Pat, I bought the same switch off ebay, mine had a wrong connector fitted so I got it cheap.

[Urban_Legend]

Installing a new ( old stock) blinker light switch set and tidying up some wiring while it's apart.

Hey Mark, I'm looking for one of those for my '84. I like the 'flash to pass' feature on the non USA version.

Do you know if you can find any more of those switch assemblies?

Hi (Again) Pat

I found my new switches incorrectly listed on eBay as a set for an FJ1200. I picked it form the choke switch on the side of it. It had been listed (29 day listings) 2 or three time. I was just lucky to find it. It was plug and play.

Mark

[Urban_Legend]

It has been a busy few weekends for me and the FJ. Last weekend I installed new gauges ( http://www.fjowners.com/index.php?topic=14375.0 ) and this weekend I have started on the 17" wheel conversion. I am still waiting on a few bits (forgot to order GSXR rear brake line) but I have fitted the back wheel up. Still not sure how I am going to do the brake torque arm. Seems to be shorter than the ones I have seen on this site (unless they were custom job. Finding a bracket to attach it seems to be the way to go. Will try a few machinery shops on Monday. I have posted a few pics. 1st pic is a before photo of the old wheel then the new wheel and a comparison shot.

Edit.....sorry for the sideways pics.

another Edit.... Hopefully I can get the "new" 89 FJ forks and front wheel on next weekend. The Callipers have been rebuilt and I am just waiting on some seals and it is all done and ready to install.

[Urban_Legend]

Hey.....I have the GSXR wheel and brakes fitted up. The torque are caused me a bit of concern, the I hit upon the idea of using a tie rod end. Quick trip to the local machinery store and with new tie rod end and a tap and die set in hand I went about finishing the job. I must say I impress myself sometimes (not hard to do  ) and it all works like a charm. The real test is when I ride the 150km to where is work this afternoon.

Mark

[Bones]

Aren't you a clever dick, a good bit of ingenuity there Mark. Your torque arm is a shorty, the one on mine is about 500mm long.

[Pat Conlon]

I dunno Mark, the swing arm wall thickness is awfully thin for the anchoring support of that tie rod end, and it's an aluminum thread.
The torque arm is going to want to pull that tie rod end piece back as the load transfers. I'm just not sure that the aluminum thread can take the recurring loading.

I would keep a close eye on it, for sure.....Gives me the heebie geebies.

[Urban_Legend]

I dunno Mark, the swing arm wall thickness is awfully thin for the anchoring support of that tie rod end, and it's an aluminum thread.
The torque arm is going to want to pull that tie rod end piece back as the load transfers. I'm just not sure that the aluminum thread can take the recurring loading.

I would keep a close eye on it, for sure.....Gives me the heebie geebies.

I will be keeping an eye on it pat. I will also be putting a locknut and large washer to spread the load a bit. And if it starts to look dodge,  I have a spare swing arm that I will get modified to suit.

Mark

[FJmonkey]

That rod end thread in the aluminum is likely to fail from fatigue, as Pat pointed out. It is only a mater of time. However, you could fab up a steel bracket that takes the same rod end and also better distributes the load and still use the same swing arm. What is the thread size of the rod end? I can make a quick drawing of what I am thinking of and post it. 

[Urban_Legend]

That rod end thread in the aluminum is likely to fail from fatigue, as Pat pointed out. It is only a mater of time. However, you could fab up a steel bracket that takes the same rod end and also better distributes the load and still use the same swing arm. What is the thread size of the rod end? I can make a quick drawing of what I am thinking of and post it. 

That would be great thanks monkey.  The thread was 10mm (metric) and bout 30mm long.

[FJmonkey]

That would be great thanks monkey.  The thread was 10mm (metric) and bout 30mm long.

It looks like this. A simple plate with a an M10 nut welded to it. This will distribute the bending moment quite a bit to the two M6 fasteners at either end.

[Urban_Legend]

Excellent.  Great work thanks FJmonkey

[ribbert]

That would be great thanks monkey.  The thread was 10mm (metric) and bout 30mm long.

It looks like this. A simple plate with a an M10 nut welded to it. This will distribute the bending moment quite a bit to the two M6 fasteners at either end.

How would the plate mount to the swing arm?

I hope your intention for mounting it is not to just tap bolts into the thickness of the arm, there's a lot of force on that and it's not always gradual.

In fact, if you are going to use a plate, you could weld a piece of metal bar along the length of the plate with a hole through it an just bolt the arm to that, you don't need the Rose joint.

The joint, screwed into a nut, welded to a plate, bolted onto the arm is making this way more complicated than it needs to be and just adds more leverage.

Knowing the forces at play here I would bite the bullet and get a lug welded to it. Go through in you mind what would happen if it let go at speed on the road.

Noel

[Urban_Legend]

We can get this right. I have a spare swing arm, and I am thinking I get a lug welded to the appropriate location and eliminate the heim joint altogether,  but that might take a while till it can get done.(have to fine someone who can weld alloy). I think monkeys fix is a good one for the interim.

Edit....I would have taken more time to get it right, but needed the bike back on the road as a daily driver. I do know this will cost me more in doller terms in the long run.

[great white]

Installing a new ( old stock) blinker light switch set and tidying up some wiring while it's apart.

Hey Mark, I'm looking for one of those for my '84. I like the 'flash to pass' feature on the non USA version.

Do you know if you can find any more of those switch assemblies?

If you're not fussy about the labeling of the switch and are OK changing the connector the 84-93 Venture has the same switchgear with that switch. It's just labelled "PTT". It's used for push to talk on the bikes intercom.

I'm using the rh switch gear to install the Venture cruise control on my 89: 



Switchgear: http://www.fjowners.com/index.php?topic=14372.msg145061#msg145061

Sorry for the little OT.....

[giantkiller]

Just cut the original mounting lug off the top. Bolt it to the arm you are using. And put it up to the Swingarm on the bottom tack it in place. Remove the arm and finish welding it and you are done.