Forking Up My FJ

[FJ12IRL]

Hi All,
I have started to rebuild the front and back end of my '91 FJ and noticed the fork seals are completely shot and were like that long before she came into my possession. I also noticed that the fork stanchions are quite badly pitted with bubbles appearing under the chrome.
I'm now thinking of maybe a complete USD front fork and rear swingarm and wheel transplant from a '92 FZR1000 might work but after a bit of research I can't find any info on it. Has anybody here done it?
Cheers in advance.

[Pat Conlon]

Yes, many of us have done it. Good info. can be had at Barry Edwards site (see the link below)




http://www.fjowners.com/index.php?action=gallery;sa=view;id=368




http://www.fjowners.com/index.php?action=gallery;sa=view;id=372

[FJ12IRL]

Thanks Pat,
What about the '92 FZR swingarm?
Anyone done that?

[FJ12IRL]

Hi everyone, since my past post about this I've sourced a 600 Thundercat to use as a donor bike mainly for the wheels and forks. I'm using the FJ triple clamps but I've noticed that they are about 10mm wider than the Thundercats.. Now spacers aren't a problem but I need a longer 17mm diameter axle.. Do any of you guys know of another axle that may fit? I'm thinking an FZR 1000 Genesis might fit, any ideas?

[jscgdunn]

Best to used the TC forks and triple.  Bolt on and you get a better fender too.

[FJ12IRL]

Best to used the TC forks and triple.  Bolt on and you get a better fender too.

I much prefer the fit and look of the stock FJ triple clamps and bars, the Thundercats clip ons are too weedy in my opinion..

[jscgdunn]

You can use the FJ handlebars.

[FJ12IRL]

Thanks but they don't  fit the TC top triple, I  tried...

[Pat Conlon]

If you find a 17mm axle and correct spacer, what's your plan on a fender?

[CutterBill]

If you need a custom axle, just take the measurements to a machine shop and have them make one. 

[woodcreekpete]

If you need a custom axle, just take the measurements to a machine shop and have them make one. 

Here's an option for keeping the FJ bars. I wanted to keep them - wasn't too keen on the dogbones or the plate. I had a machinist make up stubs to weld to the tube capnuts (not my welding, used a welder with about 50 years experience - I know my limits!). Cut the clip-ons and made up new locating stubs, welded them top and bottom. Used the existing holes in the triple to locate them. Stepped bushings top and bottom hold the stub bolts very securely. Mechanic, machinist and the welder were all confident of the strength of the set-up.