2007 R1 Front and Rear end........

[axiom-r]

I am starting to get pretty excited!!   There are more problems to resolve to be sure but a few of what I anticipated would be the toughest adaptions are complete. The shock linkage was at first looking to be some real rocket science but amazingly it is nearly bolting right in!!  I turned the stock R1 Triangle connection upside down so that the short side connects to the shock and the longer side connects to the dogbone- I'll be damned if that wasn't very close to perfect dimensions!  Now, this is a progressive rate linkage and I have no idea what I did to the rate (increased it or decreased it) so determining a spring rate will be a crap shoot- I may have to buy more than one spring to get it right.

The triple clamps were modified as previously described (I will post all the details on this later).  So with the triple clamps back in my hand I went ahead with the fist mock up- that R1 front end looks right at home on the FJ.  All the clearances are good with exception of the steering stops- they miss the frame lug all together.

I am super stoked with the results so far and pleasantly surprised at how easily this is happening....   So far my machinist friend says that I have not presented any significant challenges. I have paid him a total of $400 for the swingarm and triple clamp mods.... still need to do the fork caps, steering stops and chain carrier.

More to come!  

[racerman_27410]

have you moved the swingarm thru its stroke without the spring to see what its going to do ?

that lower shock collar looks awful close to the lever connecting to the frame off the triangle.


KOokaloo!

[axiom-r]

have you moved the swingarm thru its stroke without the spring to see what its going to do ?

that lower shock collar looks awful close to the lever connecting to the frame off the triangle.


KOokaloo!

I was quite concerned about this very issue until I looked closely at the angle and positioning of the links on the R1.  While searching for adjustable dogbones I spotted this: Stock R1-  I don't think that gap closes up when the rear suspension compresses?


I have not yet moved the swingarm through its full motion yet but I believe my set up is reasonable when compared to the positioning of the stock R1 linkage.  The rear part of the triangle gets pretty close to the swingarm mounting area too.  There could be conflict (TBD) but I think there is a good chance it will function just fine. The problem of determining the proper spring rate remains however.  The R1 rate is about 500lbs/in. the FJ would require closer to 900lbs/in.  With the full R1 linkage on there (slightly modified positioning) the required rate is unknown. I think it will be closer to 500 though.

tim

[Brook]

........ That really looks good !!

[racerman_27410]

having dealt with making a new rear suspension linkage from scratch i can say a very small difference in pickup points can have a dramtic effect on the spring rate required and whether or not the linkage action actually remains progressive.

it took quite a bit of trial and error (and revalves of my penske) in order to sort out the rear suspension characteristics on my FJ.

might just be the pictures but it looks like the shock is more vertical on the actual R1 ?..... i would definitely remove that shock spring and work the entire assembly thru its stroke before i tried riding it.

pushing down on the rear end should give you some kind of idea if you are in the ball park....


looks good though.... being a pioneer is never easy but it can be very satisfying 


KOokaloo!

[axiom-r]

might just be the pictures but it looks like the shock is more vertical on the actual R1 ?.....

You are correct about that. It would be better if the top of the shock were and inch or so rear-ward of the stock FJ position.  I thought about adding a block of billet aluminum cut into a custom mounting spacer between the existing mount and a point an inch or so to the back.  The spacer approach would weaken the top mount I believe.  I gave up on the idea because I did not want to risk any leveraging/stressing of the stock mount AND the entire system CAN bolt together as is, so.....  What do you think?  If the top of the shock came back a bit the body of the shock would be better centered through the swing arm and the linkage would be even closer to the stock R1 position.  It would also require a shorter shock that is only 11 or 11.5 inches long to fit.  I was planning on ordering my Penske at 11.75 inches (stock R1 is 12") and using the ride height adjustment and an adjustable dogbone to variably find the sweet spot.  I think I will avoid using any kind of top mount adapter unless its required or there is some tangible advantage.

[fj1289]

Excellent work!

Tony Foale (tonyfoale.com) makes some suspension analysis software at a reasonable price that would be a huge help in the design of your rear suspension.  With a little work, you could probably design a new set of "triangles" for your linkage that would give the exact amount of progression you want and get you in the ball park with your spring rates.  I used an earlier version when adapting an FZR1000 linkage and shock to my 89.

Chris

[racerman_27410]

what does it look like with the triangle rotated back to it's original position ?


even with software at some point you are gonna have to ride it to find out.... pull that spring and check for binding before you do 

KOokaloo! 

[axiom-r]

what does it look like with the triangle rotated back to it's original position ?
even with software at some point you are gonna have to ride it to find out.... pull that spring and check for binding before you do 

KOokaloo! 

In the normal position the frame mounting point is too high and the linkage binds on the bottom of the shock.  The solution would be a properly designed triangle that maintains the proportions (and therefore the progressive rate) but allows the pieces to clear. This would require the shock length to be in the 10.75" to 11" range.  I did buy the triangle for the 09 R1 (for $14) which should be here soon.  It is smaller and will present another opportunity for fitting and testing.

I promise that the wheels won't turn until the back end has a full range of motion and I am confident that the suspension is safe.

[axiom-r]

Some parts have arrived and I am trying to stay cool and be patient as the finishing line is still a ways off!  That said.....

Here are most of the rear suspension parts I have been working with.  I am waiting on a spring compression tool so that I can disassemble the rear shock and run the swingarm through its range of motion. You can see the three different stock Yamaha R1 linkage triangles I have been experimenting with.  The inverted 07 part is a direct bolt up but we still don't know how to select a spring for this new arrangement. Is the linkage more or less progressive in its new position?  Once I can make an educated guess at spring rate and we decide on a shock body length I will order a new Penske.


This is the Soupy's Custom Lowering Link shown next to the stock R1 unit. It adjusts from 6" to 7.5" (stock R1 length is 7.5" center to center) I asked Mike at Soupy's to make me a 56mm wide bushing that offsets the frame mount end all the way to the chain side.  The link arrived with both ends offset all the way to the side and I had to wait for the stock bushings to correct this on the swingarm side.  The stock bushings are in and the offset one sitting next to the link.  Total cost from Soupy was $141 shipped and with custom bushings.


Here is Soupy's link next to the stock FJ linkage- you can see the width that needs to be achieved.


Here's the Soupy's Link held in place at the frame.  This large mounting gap allows so much room for adjusting that nearly all of the offset problem related to the linkage is taken care of right there.  I will have the swingarm modified slightly- opening the triangle mount area about 1mm to guarantee that there is no binding.  After that its all about finding the right spring and valving.


****  EDIT  ****  PLEASE NOTE THAT THE SOUPY'S ADJUSTABLE LENGTH DOGBONE FAILED CATASTROPHICALLY - SEE PAGE 8 OF THIS THREAD

I am going to start taking apart more of the rear end so that I can begin installing the new exhaust system.  I had the Delkevic Collector Box is SS already and the Delkavic Mufflers that I wanted so I went ahead and bought the SS Down tubes and 4 into 1 connector pipe from SandyBikeSpares UK ebay.  The 4 into 1 is for XJR1200 but I read that another member here mounted it fairly easily on the FJ so....  Not sure which way I'll go yet two mufflers or one.

[AustinFJ]

Wonderful work!  And that exhaust looks pretty cool!  A 4-into-1 with the stock (or similar) header pipes.  Would love to hear how it sounds when you are done.  Get this stuff going!  This has got to be one of the best times for rides in your area (not that there is ever really a bad time  ) Of course, don't rush.  From the looks of the project, you've got the "detail oriented" view that'll make this pretty awesome when finished!

Greg

[fjman]

your making me jealous .. keep up the good work 

[andyoutandabout]

Gosh, and mine's just getting a fork brace sometime this year.
Watching this build is more engrossing than Coronation street.

[axiom-r]

  well in my defense it was either buy a new bike (a used Aprilia Futura) and sell the FJ or modify the FJ....  I went the modify route. Hopefully it turns out as envisioned.

[candieandy]

I will get some pictures of my FJ R1 swingarm in late April. I live a few hours away from it right now and won't be home til then. But i will say i went thru the same process you did with the rear linkage geometry angles. i spent a lot of time looking at angles and which way the linkage needed to be to create the right leverage on the rear swingarm, instead of the rear shock. I was home a few weeks ago and tried what you had done with the upper shock mount. it was too much leverage and the rear end bottomed out fast with a lot of bounce. i know you said you didn't want a upper shock mount extension, but thats what i have and it has fixed the leverage issue. i will post as soon as i can. in the mean time keep it up, the bike looks great