3Zx14w

[jscgdunn]

Thought I would start this as work as ground to a halt with WTI below $40.00.  Going to be a tough few years here in Alberta, I think, as we are going into a "bust"....

This all started while trolling on Kijiji and came across this:




The ad sat there a long time; I finally offered him $400 for everything and he took it.  Included was a complete front end except calipers, which is what I was really after.  I then re-posted the frame and ended up selling everything except the front end for $400. Sometimes a blind squirrel finds a nut!

As per the other front end post the triple tree stem is about as close as you can get to the FJ:



Here is it mocked up in an 84 frame:



and a close-up:



The bottom bearing race is the same as the fj, but the stem will have to be turned down for the top bearing.

Off to the lathe guy.....

[jscgdunn]

Forks
Documented the fork measurement. From centre of axle to bottom of fork cap, the FJ fork is very close to 32 inches.  The zx14 forks are 29.5 inches.  Similar to the FJ.  A two inch extension (http://www.cycleoneoff.com) will be required The top of the tube is 50MM;  the portion at the lower triple is 54 MM.











Got out for a ride last evening up Powderface Mountain; no traffic but we have the smoke from Washington Idaho forest fires.  George has not put them out  yet.

[giantkiller]

I made my extensions 3 1/2" long so I can slide the clippons I made. Up for touring. And back down for the twisties. You can make clippons with the same dimensions as the fj handlebars. Just cut off the zx bars from the clamp portion of the zx clippons. Make the risers and get 7/8" bar stock for the bars themselves. Weld it up and your good to go.
I have my original 50mm extensions for sale. If you want em.
Dan

[jscgdunn]

Thanks Dan, I will send you a pm.

Jeff

[jscgdunn]

Been a long winter and project has been coming along in fits and starts.  Pretty much there.  Just exhaust and the Xjr1300 sprocket cover to install.  Here is a preview shot.


Now we will scroll backwards.  I did get the for extensions from Dan and they worked perfectly.  Also had to add 1.25 inch risers to the ZX14 top triple.  As shown in the earlier picture, the triple stem required only the top turned down.



If you look closely you might notice the controls are form the ZX 14.  I went to Eastern beaver and got the right plugs and adapted them to the FJ wiring harness.

Here is a close up of the front end installed.



Now the back end.  This was by far the most challenging.  I wanted to try to avoid the upper shock mount issues so I choose a 2008 CBR600RR swing arm.  Good news: the axle diameter is the same so the CBR axle worked fine.  a host of other challenges, however.



1) I had to make a hanger for the rear caliper.  1/4 inch aluminum plate.  Also had to make the stay which is connected to the spool mount.
2) The ZX14 wheel is six inches.  Turned down the sprocket carrier 1/4 inch.
3) Had to use a 1/4 inch offset front sprocket.
3) XJR shift shaft and clutch push rod and XJR sprocket cover.

[jscgdunn]

Here are a few pics of the swingarms for comparison.  With all the internals, the CBR swingarm is 10 MM wider than the FJ swingarm with the end caps on. Without the chrome bushings the width is identical. I turned down the chrome bushings on 4mm each side so they protruded only 1mm.  Fit was tight.

[jscgdunn]

The cbr swingarm is much wider than the FJ.  Notice how the subframe looks a bit different?  No close ups here because my mig welding skills are at the rookie stage.  Also, the rear brake master interfered as well.  I ended up using an 2008 R6 master which is configured differently. 

Of course the stack batter location is also an issue, so I moved it forward.

[jscgdunn]

First Ride



Got out yesterday for about 20 miles.  Everything worked good and very stable, but a bit ponderous feeling (ie like a Harley) at low speeds.  Rear wheel is only about 1/2 inch off ground on centre stand.  I think that dropping the front should lighten it up.  Advice welcome!  Jeff

[jscgdunn]

So dropped the front 2 CM, (which is the max I can with Dan's fork extensions, unless I trim them shorter).  Fork length now should be very close to standard FJ, and rear wheel about 1.5 inches off ground when on centre stand.  Front of bike Noticeably lightened up, but still some adjustments to make I think.

[FJ1100mjk]

First Ride,...but a bit ponderous feeling (ie like a Harley) at low speeds. 

Something that you'll find in a bike with a 27.5 degree steering stem angle. Quite stable at speed, however, and it will track true with little input while tooling down the highway.

I'm enjoying the pictures and the updates. Full steam ahead!

[mish]

I fitted a cbr600 07 swingarm on my fj project.when I used the unit pro link,the shock was hitting the fj Shock mount on testing the stroke of the swingarm.
I'm using soupys adjustable link.no matter how I adjusted it the shock hit the frame mount,at maximum stroke.
Did your shock hit the frame shock mount on test?my fj is a 3CV.

[jscgdunn]

Good question.  This was a concern, however, after cutting off the battery support portion I was able to get seven inches of wheel travel (ie shock not attached). Here is a picture of the mounts with 2 4X4s under the back wheel.




Avoiding using the original mount was the goal of going with the Honda swingarm, but I am not brave enough to cut the shock mount off!

[mish]

Yes that looks ok.i have a balance free cbr1000rr 2012 shock.i attached it to the fj shock mount and the link of the cbr600 swingarm.i inverted some R1 06 link plates to the soupy adjustable lower dog bone.i have tested this the stroke without the spring and it's fine.i have got an up rated for spring that fits the Honda shock.
I'll take some pics of mine,when I can.

[FJmonkey]

Avoiding using the original mount was the goal of going with the Honda swingarm, but I am not brave enough to cut the shock mount off!

You may not need to cut any more, figure out the shock mounting position and max travel next. That will tell you if you need to make more room for travel.

[jscgdunn]

Yes that looks ok.i have a balance free cbr1000rr 2012 shock.i attached it to the fj shock mount and the link of the cbr600 swingarm.i inverted some R1 06 link plates to the soupy adjustable lower dog bone.i have tested this the stroke without the spring and it's fine.i have got an up rated for spring that fits the Honda shock.
I'll take some pics of mine,when I can.

Be interested to see.  I too tried both R1 and R6 link triangles but they were too short.  I found that the CBR 600 triangles inverted were pretty close.  I do have an adjustable dog bone ordered for more tuning, but it is on the slow boat from China.  At present using CBR 600 dog bone.