FJ1100 fork conversion

[bikerphil]

Mod completed

This mod took a lot of time and hard work, but the end result was well worth it. This bike is soooo much fun to ride now. She'll take turns now with lightning fast response, and the ride can be dialed in to suit your riding style in a matter of seconds. Total cost, not including tools, about $150.

[DGXSER]

Very nice Mod Phil!!! Awesome job making the parts to!

Now if it only had a front fender (I know, dang engineer sweating the finer details.)

[bikerphil]

Very nice Mod Phil!!! Awesome job making the parts to!

Now if it only had a front fender (I know, dang engineer sweating the finer details.)

Thanks man, I was test riding in the rain a bit yesterday, the water comes right up off the road and hits you square in the face. I'm gonna try to incorporate the XS fender onto the fork brace somehow, maybe shorten it a little. The bike rides friggin' awesome, the wider stance helps tremendously.

[DGXSER]

When you have a chance, I'd love to see some more overall pics with the new look.

[81xsproject]

Are these forks larger diameter? otherwise, I am not sure I see the real benefit beyond better dampening, which, at $150 you could afford emulators. What about fork angle? I really like this mod as it allows retention of the stock wheel.

[bikerphil]

Are these forks larger diameter? otherwise, I am not sure I see the real benefit beyond better dampening, which, at $150 you could afford emulators. What about fork angle? I really like this mod as it allows retention of the stock wheel.

These fork tubes are 41MM diameter, and are further apart from each other in the triple trees. Stock XS forks are 37mm, but I'm sure you know that. The fork angle is the same or just slightly less than stock. The fork legs have to be bored out to 17mm to retain the stock wheel. The FJ fork uses a 15mm axle. A 15X47X14 wheel bearing does exist, but is rare and hard to get. I'll have some more pics shortly.

[bikerphil]

couple more pics

I'm waiting for the fork brace piece to be sent from Miami, then I'll start figuring out how to mount the fender. These forks are slightly shorter than the XS's, but don't need to compress as far in travel to operate. They lower the bike just the perfect amount.

[DGXSER]

Awesome job Phil. If no one told you, you'd think they were stock till you realized they sit a couple inches shorter. Looks like a runner for sure!!

[petejw]

Youve done a really good job there Phil,
the ride height looks sweet too.

must of missed it somewhere,
but how did u go about drilling the forks for the axle?

[bikerphil]

how did u go about drilling the forks for the axle?

I drilled them out in 3 steps with a cheapo benchtop drill press. 5/8" first, then 21/32", last a 17mm bit. It went pretty smooth. If I was to do it again, I'd either use a hone or take them to a pro.

Now I'm having problems with the damping circuit on one fork, so I have to build a tool to dismantle them next.

[jmnjrpa]

They look good. I just can't understand how they are supposed to stiffen the forks?

[bikerphil]

They look good. I just can't understand how they are supposed to stiffen the forks?

Larger diameter fork tubes + further spacing apart from each other = more stability, less fork flex.

I just got done disassembling the forks themselves and found that the PO had put them together improperly. The two forks were damping at different rates which resulted in a shimmy when cornering. I believe I got it all sorted out. Time for a test ride again. Nice thing about these FJ forks is that all the bushings and most of the internal parts are still available, for now.

[bikerphil]

OK, got the fork brace today and installed it with some nuts as spacers to raise it up to about 8MM above the tire. Gonna get goin' now on chopping the original fender mounts down and adapting them to fit the fork brace mounting holes. The fender will sit over the brace hiding it. Some more pics....

[Cobia]

Looks tight

Phil,
The bike looks really tight, kind of gathers it all in. Knowing your skills, I know you'll have no problems modifying the fender. Question though, I don't see any dust caps/seals on top of the lower portion of the forks?? Does it use them? Missing??
Overall, great job, hope the ride is as good and you can get over those internal problems soon.

[bikerphil]

Question though, I don't see any dust caps/seals on top of the lower portion of the forks?? Does it use them? Missing??

Yep Robert, they were missing when I got the forks. The oil seals are fine tho. Those dust wipers will be last on my list of things to do. Now I gotta fix the leak in the 750 FD. Might as well put on my new rear tire when it's apart.