02-03 R1 Forks

drawkward · March 31, 2009, 04:10:46 PM

Anyone know if the front forks from an 02-03 R1 will fit on the '89 FJ1200??

There's a set for sale on Craigslist and I'd love to get them if they'd fit. The forks on my FJ right now are bottomed out (that's how I bought it) and it's got to be the sketchiest bike I've ever ridden because of it.

Thanks a lot!

Jon

andyb · March 31, 2009, 04:24:07 PM

Tear them apart and see why they're bottomed out?

Anything will fit if you put enough energy/money into it....

the fan · March 31, 2009, 04:24:42 PM

not as a direct bolt on. no.

why not fix yours?

drawkward · March 31, 2009, 04:29:43 PM

Well, I planned on fixing them, or at least getting them fixed. Total if I get someone to do it is going to be around $200. If another set of forks bolted up I'd rather just do that if it was cheaper. I guess that's the driving factor...money.

The original forks that are on there don't seem to be leaking any oil whatsoever, but I guess it's possible that all of it leaked out or that the springs internal to the fork are bad. I've just never worked on forks before and am a little hesitant to jump into the process without any prior knowledge...know what I mean?

But what do you guys think...I have mechanical knowledge on motorcycles...but forks I've never actually done. How hard is it?

I have the forks ready to slide out of the triple right now, I just don't know anything about the internals.

Thanks for the quick responses too, this forum is pretty awesome.

racerman_27410 · March 31, 2009, 04:33:40 PM

nothing to working on the forks..... i think you should go into them.....a new set of fork springs is right at 100 bucks.......

if you have any questions you can always ask here.

KOokaloo!

Frank

drawkward · March 31, 2009, 04:41:18 PM

Ya....I think that's a good point. Well, it didn't take too much pushing to get me to do it.

After work I guess I'm gonna tear them apart. Does the front fairing need to be taken off? Any sage advice anyone can offer is whole-heartedly accepted and welcomed!

Paul Dodge · March 31, 2009, 05:46:18 PM

Hi Jon,well as one of the fellows has said a set of springs are about $100. While the forks are still on the bike (or at least while you still have the springs under tension) get your impact wrench if ya have one and the proper size socket head (allen) socket and break the bolts loose in the recess at the bottom of each leg. Then you can loosen the caps on the top of each leg ( they'll be under spring pressure so be careful!) It takes a fairly large tool to loosen and unscrew the caps on top.I've made a tool out of the proper sized metric bolt & nut brazed or welded together. Ya may as well replace the seals while your at it and drop the stem (bottom triple tree) and clean and check the tapered roller bearings. Repack them with a good quality wheel bearing grease. Make sure you snug the bearings to a point where there is no"play" in them but don't over tighten them. Good luck! Paul

racerman_27410 · March 31, 2009, 07:53:51 PM

if the seals arent leaking you dont have to take the forks apart to change the fork springs..... you just have to take the top caps off..... dont remove the fairing just loosen the pinch bolts on the upper (makes it a bit easier if you loosen the fork top caps before you loosen the lower pinch bolts and slide the forks out.... tie up the brake calipers so they dont hang by the lines.

once you get the top caps off the springs just slide right out.... turn the forks upside down and pump all the oil out.

replace oil with some good 10 wt fork oil.... 6" from the top of the fork tube with the forks collapsed.... slide new springs in (you will probably want 10-15mm of preload)

replace fork top caps.... re install forks on bike.

easy peasy

Frank

drawkward · March 31, 2009, 08:55:54 PM

Hey guys. I got the forks off pretty easily.

For the sake of archiving what the top cap tool should look like, here are some pictures of mine:

(please excuse the sloppy welding, I only started a month ago)

As for the forks themselves....one of them came apart fine. All the seals look good to me, as far as I can tell. But the other fork had a problem. However, I don't know how the hell it happened or if it caused the forks to bottom out. Maybe you guys can help diagnose it. It seems the rod that is attached to the endcap has managed to free itself from the little notched hole it is supposed to reside in and wedge itself in one of the slots on the outer ring. I'm unsure how this could happen as I bought the bike as-is. I haven't tried to dislodge it as I wanted to confer with you guys first. Anyways, enough talking...here are the pics:

Here's the entire fork assembly with the spring:

Thanks in advance for any help!

RichBaker · March 31, 2009, 10:09:34 PM

Looks like PO had the forks apart already... The rod goes into the D-shaped hole in the center of the adjuster(in the damper rod). he didn't get it in the right hole, so it prob'ly puts the fork in a bind. Put it back together correctly and it'll prob'ly work as it should.
I'd replace the springs anyways, they are only marginal for an FJ, and the correct, straight-rate springs make a HUGE difference in the way she handles...

Marsh White · March 31, 2009, 10:16:32 PM

Good observation Rich! Yeah, it is kinda a bitch to get that rod in the right hole.

racerman_27410 · March 31, 2009, 10:30:23 PM

Quote from: Marsh White on March 31, 2009, 10:16:32 PM
Good observation Rich! Yeah, it is kinda a bitch to get that rod in the right hole.

its worse than a bitch to get that rod in

and the way that one was in the pics i'm sure it was binding the fork......

i cant believe the bike was even close to rideable like that

KOokaloo!

Frank

drawkward · March 31, 2009, 11:53:39 PM

Thanks. I've come to expect this type of fast knowledge from you guys.

I was planning on buying these progressive springs:

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=200317021866&ssPageName=ADME:X:RTQ:MOTORS:1123

But you guys think I should get a straight rate spring instead? Where would I go about finding these as no one on Ebay sells them from what I can tell. Is there a good place to shop for the FJ?

Thanks again

Marsh White · April 01, 2009, 12:17:41 AM

Yes, if you are spending the money anyway, you should DEFINETLY get the straight rate springs...maybe a touch more money...if that. The FJ is just too damn heavy to make the progressive springs any good. The main company that makes the straight rate springs is Race Tech: http://www.racetech.com/

I don't know where the cheapest place to buy them is...LOTS of places sell them...pretty much any MC dealer in the US. Others can help you with the correct rate for your weight, but 1.0kg is a good neutral.

tqmx1 · April 01, 2009, 12:27:39 AM

I don't know why no one else has brought it up but you should up date the forks with Race Tech emluators(it damm near makes cartrage forks out of the 1930s damper rods) It's $170 well spent.

And it's still cheeper than the $360 for the compression & rebound valves + oil & small parts for my FZ1 forks

Do it once and do it right.

News:

02-03 R1 Forks

the fan