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fork seal question

Started by 5speed, August 21, 2021, 04:34:22 PM

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FJ_Hooligan

Put an '89+ front wheel and forks on it.  Still the most transformational mod I ever did to my '85 FJ.

You'll need the wheel, spacers, axle, brake calipers (or upgrade to monoblocks) and the fork sliders.  You can use your tubes.  Good time to put is straight springs and RPM fork valves.

The difference in handling was night and day.
DavidR.

5speed

called my local yamaha dealer to order the seals and bushings. he couldn't find the lower one on his search...is #83 the lower bushing? they are calling it a piston.
https://www.dealercostparts.com/oemparts/a/yam/500427d3f8700209bc788b1f/front-fork
1986 FJ1200
2000 Roadstar
1976 GL1000
1978 GL1000
1982 GL1100 (sold)

racerrad8

Quote from: 5speed on September 02, 2021, 06:58:29 PM
called my local yamaha dealer to order the seals and bushings....

Here is everything you need to rebuild your forks: RPM/FJ 41mm Fork Rebuild Kit

Plus there's an option of upgrading to the wiper with the build in fork protector.

Randy - RPM
Randy - RPM

5speed

Quote from: racerrad8 on September 02, 2021, 10:00:11 PM
Quote from: 5speed on September 02, 2021, 06:58:29 PM
called my local yamaha dealer to order the seals and bushings....

Here is everything you need to rebuild your forks: RPM/FJ 41mm Fork Rebuild Kit

Plus there's an option of upgrading to the wiper with the build in fork protector.

Randy - RPM
I looked at those Randy but between the exchange rate and shipping it gets to expensive in a hurry.
1986 FJ1200
2000 Roadstar
1976 GL1000
1978 GL1000
1982 GL1100 (sold)

5speed

finally got the fork seals done.
Question for Randy.
I have a pair of your risers on their way. Do I need to raise the forks up in the triple tree to get enough tube for the risers and bars?
I didn't want to finish putting the front wheel,calipers back on incase I do.
1986 FJ1200
2000 Roadstar
1976 GL1000
1978 GL1000
1982 GL1100 (sold)

RPM - Robert

No, the RPM cap lets you clamp onto the cap and not have to move the forks up. I usually leave the fork cap itself just above the upper triple and install the risers from there.

5speed

Awesome. Tks for the info.
1986 FJ1200
2000 Roadstar
1976 GL1000
1978 GL1000
1982 GL1100 (sold)

5speed

she was due..
the bushings weren't to bad but I replaced them anyway.
1986 FJ1200
2000 Roadstar
1976 GL1000
1978 GL1000
1982 GL1100 (sold)

FJmonkey

That bushing is very worn out. The dry lubrication (PTFE) on the inside is nearly gone. That means metal on metal contact. Glad you changed it out.
The glass is not half full, it was engineered with a 2X safety factor.

'86 Ambulance - Bent frame, cracked case, due for an overhaul
'89 Stormy Blue - Suits my Dark Side

5speed

Quote from: FJmonkey on May 19, 2022, 10:25:58 AM
That bushing is very worn out. The dry lubrication (PTFE) on the inside is nearly gone. That means metal on metal contact. Glad you changed it out.
that lower bushing must spin a lot on the fork tube to wear the inside like that?
1986 FJ1200
2000 Roadstar
1976 GL1000
1978 GL1000
1982 GL1100 (sold)

Firehawk068

Quote from: 5speed on May 19, 2022, 02:46:21 PM
Quote from: FJmonkey on May 19, 2022, 10:25:58 AM
That bushing is very worn out. The dry lubrication (PTFE) on the inside is nearly gone. That means metal on metal contact. Glad you changed it out.
that lower bushing must spin a lot on the fork tube to wear the inside like that?

That larger bushing stays pressed into the lower (outer) fork-leg. This slides up and down over the upper (inner) fork-tube, so the inside wears out.

The smaller bushing stays locked to the end of the upper (inner) fork-tube, and slides on the inside of the lower (outer) fork-leg as it moves up and down, so the outside of the bushing wears out.
Alan H.
Denver, CO
'90 FJ1200

5speed

finally got her all back together. I was waiting for these to arrive before I buttoned it up.  :good2:
1986 FJ1200
2000 Roadstar
1976 GL1000
1978 GL1000
1982 GL1100 (sold)

5speed

The other repair I did was the front fender mounting tabs.
I read quite a few threads here about this issue and I actually found a bandit fender on e-bay but between the price and shipping it was going to be over $100 so I decided to fix what I had.
I used abs cement and pieces of a sheet of abs I got on amazon.
Once I had the repairs sanded down I reinforced the tabs with more abs cement and fiberglass mesh drywall tape. I use it quite a bit and it works very well for jobs like this.
When I put the fender back on I used these washers that have a piece of rubber bonded to them. I snugged them up but not extremely tight. I'm thinking the rubber will give the fender some wiggle room and prevent more cracking.
1986 FJ1200
2000 Roadstar
1976 GL1000
1978 GL1000
1982 GL1100 (sold)

chiz

Quote from: FJ_Hooligan on August 31, 2021, 12:15:03 PM
Put an '89+ front wheel and forks on it.  Still the most transformational mod I ever did to my '85 FJ.

You'll need the wheel, spacers, axle, brake calipers (or upgrade to monoblocks) and the fork sliders.  You can use your tubes.  Good time to put is straight springs and RPM fork valves.

The difference in handling was night and day.
On more than one occasion riders have said how well the early fj's handled. Found the opposite with mine never knew what
the issue was compared to my late ST 1100 it was scary though I'm not a brave soul. But thanks to members here I changed my wheels brakes suspension and forks early GSXR and later FJ 12...... What a transformation.
   Lez

5speed

Quote from: chiz on May 27, 2022, 12:04:49 PM
Quote from: FJ_Hooligan on August 31, 2021, 12:15:03 PM
Put an '89+ front wheel and forks on it.  Still the most transformational mod I ever did to my '85 FJ.

You'll need the wheel, spacers, axle, brake calipers (or upgrade to monoblocks) and the fork sliders.  You can use your tubes.  Good time to put is straight springs and RPM fork valves.

The difference in handling was night and day.
On more than one occasion riders have said how well the early fj's handled. Found the opposite with mine never knew what
the issue was compared to my late ST 1100 it was scary though I'm not a brave soul. But thanks to members here I changed my wheels brakes suspension and forks early GSXR and later FJ 12...... What a transformation.
   Lez
If it was going to be my daily rider I would look in to those mods but it isn't. It's for rides when I need to feel that kick in the pants acceleration plus I ride at my skill level which isn't anywhere near good enough to really push the bike.
1986 FJ1200
2000 Roadstar
1976 GL1000
1978 GL1000
1982 GL1100 (sold)