FJ1100 Project; fixing stripped out threads on front brake caliper, the hard way

[SuperBanjo]

Hi there!

So I'm new to this forum, and also to the FJ 11/1200's. Got the Beast into the garage about a week ago, started the teardown and noticed some future projects as I went along.

First off was getting a new pair of shoes, so I went for some Metzeler Lasertec, bias-ply, standard dimension. As the wheels came off, I had to remove the calipers, and then I noticed that one side had two different sized bolts. So this is where the first real project starts.

The first thougt was to just weld up the bolt hole, re-index in the mill and make new holes, but then I came to think about making stainless thread inserts, since the fork also have bigger holes that would also need fixing.

Making S-S inserts for the caliper, preparing the caliper and making bushings for the fork is what will be going on in the following weeks, hope some of you will come along for the ride and maybe add some thoughts and tips as we move along with the rest of the project(what next is still to be determined).

Pics and drawings coming up 


-Pål

[red]

-Pål,

That's a good first post.  Welcome to the FJ campfire!  Be among friends here.      

You may wish to search for newer, better calipers than what you have now, instead of doing that machine work on old stock. 
There are lots of possible caliper upgrades, and this crew probably knows most of them.

Cheers,
Red

[FJ1100mjk]

If you can, just source another used caliper from eBay. Cheap. 

[SuperBanjo]

Thanks for a warm welcome 

I was thinking about getting a pair of replacement calipers, since the stock seem to be known for lack of bite, but with 25% import tax on foreign products, the diy-option is the first choice until I decide on replacing them.

And also it makes for an opportunity for me to try some different takes on low cost  projects, and hopefully an interesting project thread 

What replacement calipers are out there, and what do you guys recommend?


-Pål

[SuperBanjo]

Quick update!

Just got an appointment at the local metal-doctor, heading there for a (not so) quick chat about mostly anything, and some relevant to the project.

The plan is to make some sort of insert in the caliper, and a guide bushing for the hole in the fork. Exactly how it is to be done will be determined at a later point, but I'm heading towards a thread insert with a flange which is recessed in the caliper, so there is something to pull against that won't slip out. The other idea was an interference fit, but not sure if the aluminum casting would hold.

Pics are coming, running out of daylight, but luckily we have electricity not far from here

And for plan B, What replacement calipers do you guys recommend? Might be interested in 4 pot clamps for the front if it's available for a reasonable amount of money.

-Pål

[SuperBanjo]

So, after a (not so) short visit at the doctor, the stripped caliper is once again ready for service!

The caliper was indexed and drilled to dimension, both holes threaded to UNF1/2"-20 to preserve enough material around the inserts. Threaded inserts where made with UNF 1/2"-20 outside, and Yamaha standard M10-1,25 inside and secured with Loctite 

The caliper had also seized solid, so had to get it unstuck with a lot of elbow grease an cleverness.

Pics follow:

[SuperBanjo]

Time for a short update!

The fix seems solid, no sign of anything coming loose

Next up is fitting steel braided brake lines, any good source for getting a full set? I've looked at the sets from fjcatalogue.com, seems OK but are there any other dealers out there?

-Pål

[red]

Next up is fitting steel braided brake lines, any good source for getting a full set? I've looked at the sets from fjcatalogue.com, seems OK but are there any other dealers out there?
-Pål

Pål,

It may be better (and less expensive, and faster) to have the local hydraulics shops (not bike shops) making your new steel-braided lines.  They should have the new banjo ends which can twist to fit, and a variety of finished colors, if you want a custom appearance.  You will also be able to have the lengths changed to your exact specification, if you need some slack where they are installed on the bike.

[SuperBanjo]

That might be just what I'll do, Red!

I'll have to check the prices locally first, but things seem to be in the price range from about an arm, up to all three arms and a leg around these corners. That's also the reason for starting the ''repair stuff the hard-but-cheap-way''-thread :-) New calipers from ex. fjcatalogue, which is closest to home, is about $702 for the pair of six-pot, then add shipping, import tax and handling.

But, now she is fit for the road

I'll hit the shop to make her stand steady on sand and gravel, the sidestand is getting a small job

-Pål

[Motofun]

Thanks for a warm welcome 

I was thinking about getting a pair of replacement calipers, since the stock seem to be known for lack of bite, but with 25% import tax on foreign products,
-Pål

Curious....does that 25% import tax apply to used parts and used prices?  Yamaha Blue spots can be had on e-bay for less than $100USD although they may have to need a rebuild and new pads.  By the way, which year FJ?  The '84/85 models with the useless anti-dive is ripe for an additional mod to delete the extra unsprung weight....just make sure to connect the upper and lower ports with a block that has a drilled bypass.

[balky1]

That might be just what I'll do, Red!

I'll have to check the prices locally first, but things seem to be in the price range from about an arm, up to all three arms and a leg around these corners. That's also the reason for starting the ''repair stuff the hard-but-cheap-way''-thread :-) New calipers from ex. fjcatalogue, which is closest to home, is about $702 for the pair of six-pot, then add shipping, import tax and handling.

But, now she is fit for the road

I'll hit the shop to make her stand steady on sand and gravel, the sidestand is getting a small job

-Pål

Try here since you are from Europe: https://www.biketeile-service.de/

[SuperBanjo]

Curious....does that 25% import tax apply to used parts and used prices?  Yamaha Blue spots can be had on e-bay for less than $100USD although they may have to need a rebuild and new pads.

The import tax is a bit misleading. VAT is what I mean in this case, which is to be paid on any product bought from outside Norway, with a few exeptions.

The general (simplified) rule is that anything with a value of more than $40 INCLUDING shipping, handling and insurance is added 25% VAT and a fee for the process upon customs clearance, even if used.

Yes, it is the model with anti-dive units, they are still working but a fork-swap is something i consider. Also the option of blanking is in mind, but that will be for later

-Pål

[GS Jockey]

Hi Pål,

Just a thought for the future, possibly... Where abouts in Norway are you? I was going to be coming over there for three weeks in June, for a ride up to Nord Kapp, then back to Oslo via Lofoten. But unfortunately my riding partner had a serious accident in February, so I cancelled the trip. However, she's showing every sign of wanting to get back on a bike, so I'm hoping to make the trip next year.

Now I know that's a long time off, but I may be able to get small parts (calipers?) and bring them over for you. No-one need know, if you get my drift. I believe one 'mod' some do is to replace the 1100 forks with those from an 88-on model 1200. No anti-dive, and you can fit the R1 Blue or Gold spot brake calipers. (Beware the dreaded 'Moditus', it's not just an American disease...)

Was out in Norway a couple of years back, and was surprised to meet up with an FJ1100 on our way up to the Aurland-Laeredal 'Snow Road'. I'll post a picture some time.

Dave.

[SuperBanjo]

Hi Dave!

Sorry for the delayed response, have had a serious case of Kawasaki in the garage, which took up mostly all my spare time.

Absolutely an idea for the future, I have no hurries :-) But a different set of calipers, or other parts for that matter are always welcome!

I live just south of Trondheim, more or less on the way to Nordkapp.

-Pål