Taking the plunge: R1 Fork Conversion

theWolfTamer

theWolfTamer

Wizard
thewolftamer71.blogspot.com
After dumping the bike in January due to some embarrassing inattention, I started thinking about how fragile these machines are. If I'd damaged my bike beyond repair, after crying I don't know what other bike I want. I see myself owning my Gen1 for a very, very, very long time. Since that's the case,
I might as well make it exactly what I want it to be.
:thinking:

With that in mind, I contacted Justy on the UK forum to get the spacer shroud necessary to fit R1 forks to the Gen 1 after reading about them in this thread: R1 Fork Conversion Guide in TECH & MODIFICATIONS Forum.

My plan was to troll eBay, the r1 forum, and craigslist (or any other place you might suggest) for a good deal on the rest of the parts and collect them until I had them all. I figured it would take as long as it took and I wasn't going to miss a meal just to get pretty forks on the bike. The idea was to move slow but since I made the decision to go ahead, everything has been traveling pretty fast!

Yes, I want them just because it looks good!

Yesterday I found a steal of a deal on 02/03 5pw forks with lower triples that I couldn't pass on. :drools: They're leaky and have 20k on them. From the pics they look to be in great shape otherwise. Here's the steal part: they are about $300 cheaper than comparable sets on ebay that aren't leaking!

Since Cruzman would make me service any forks I bought before putting them on the bike :deal:, I didn't think them leaking was a big deal. To confirm my thoughts, I got opinions :2cents: and tips on what I needed to ask to be sure they were what they appeared to be. One :nono: and I would have let them go since I'm not going to be using them until I get the rest of the parts.

I bought them tonight and am waiting for them and the shroud to arrive.

I have one question though. Reading through the Guide, Falcon mentions getting an engineering shop to press the stems out of the triples so you can use the fz1 stem in the r1 triples since most owners won't have a large hydraulic press or lathe.

I avoided the lathe part by buying the spacer from Justy, but what kind of shop do I go to to get the stems swapped? (No, I don't know what an engineering shop is, that's why I'm asking).

It'll be a while before I do this as I still have a few more parts to collect. I figure slow and steady wins the race.

Here are pics of the forks I'm waiting for:
photo2.JPG
download3.jpg


So far I have spent less than $250 to get the forks, lower triples, and spacer. I just need the axle, fender, top triple (either 5pw or gen2 fz1), and an extra fz1 steering stem. :shine:
 
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Question

I, too, love my 09 FZ1 and have set about making it as good as I can afford to. So far, the Ohlin rear shock has been the big buy. But changing the front end I am less certain of. Given that it works ala MotoGP bikes, where one tube is compression and the other is rebound, is it indeed better to put on a higher end R1 which does not work that way and therefore has "cross talking" limitations, or to modify the stock tubes with better springs and valves? Just wondering.
-MW
 
I've thought about this several times but with the Gen II, the R1 forks are shorter so I'd have to lower the rear or suffer with straight-line handling. Since the bike is the proper height for me with almost all stock parts, I'm leaning more toward better springs and changing the fork oil to a slightly heavier weight to reduce dive.

Many have swapped out the forks and most love the conversion. I don't think you can go wrong either way, it's more a matter of personal preference. Often times, as Patrice is finding, it is cheaper to swap than it is to build out the stock forks. With cost a factor, getting springs and re-valving/replacing the valves can be an expensive endeavor. Working with used equipment and replacing the cheap parts like the seals, etc... can be an inexpensive answer to a handling problem you want to address.

I'm subscribed and want to follow your build here! Good luck and keep the pictures coming as you start this process. :tup:
 
I am interested to se this conversion as well. I did some checking at this years bike show, and found a suspension specialist in BC that has done FZ's before. He deals with Ohlins as well as Penske. The next time my bike heads past he says to call ahead and he will do it while I wait. He has a set of internals ( Ohlins cartridges) for my bike in stock. If it makes as much difference up front as the rear did it will be worth the money.

Your project should prove more bang for the buck though. For riders that keep their bikes for long periods of time it is so much easier to justify the expenditures (like me). Suspension is the one area that is so often overlooked and the single best modification / improvement that can be made. Anyone who has spent the money knows this.
 
I always love to see fork swaps!

I don't have an FZ1 (yet) but I am in the middle of a lengthy fork swap on my FZ6 (Changing over to the Kawasaki ZX6R BPF fork). I have had to press-out the steer tube and have it machined to match the stock tube of the FZ6. You had asked where you could get this done; My answer, pretty much any machine shop, fabrication shop, weld shop, and even most automobile repair shops. A standard 20 Ton hydraulic press will do the job and they are found in most industries which require removal/installation of bearings. I found a great local guy (he used to make the molds for Parker Brothers Plastic Game pieces, Monopoly, etc...) by asking around. Networking can be your friend.

Good Luck with the swap!
 
Sounds like a similar process to what I will be doing. Pressing out the r1 stem and replacing it with the fz1 stem. Not machining it to match though, will be using Justy's spacer shroud to mate with the upper--either g2 fz1 or r1. I'd like to find a g2 upper because they won't need to be modded to add handlebars.
 
wolfie see my notes on your blog also that upper tree looks s££t

i'd prefer it to look like this as it hides the mod

2lbp5q0.jpg


291yyjm.jpg


Ignore the bottom tree as you can use the R1

advantage - the fork leg is half wat down the tree but hidden - easy to mount risers - looks trick - no need for spacer as tree made to suit

disadvantage - cost maybe (not sure on prices stateside

just my ramblings (but then wot do i know lol)
 
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I like that Luke! It needs to be black, but it still looks good. It also looks like it costs a lot, no matter where you're at. I'm trying to save the last $$$ I need to go to Alaska this summer. After that, I'll be focused solely on this mod.

ATM, I still haven't truly decided what to do about the upper yet. I really don't like the looks of the stepped upper, so I will be taking your advice about the extensions. tqmx1 on the other forum says you can use the gen2 upper. I believe him but I don't quite understand his explanation. Something else to add to the list to learn before I get started. (I studied Falcon's guide for months before deciding to do this. Heck, I'm still studying it!)
 
From memory was about 600 bucks but that was top and bottom

i did go black in the end lol

jhg9i8.jpg


i'm intrested in the slug idea also but from the photo i cant see how it clamps
 
dinstances

oh guys I'm so afraid to live soo far from you..when I buyed my genII first of all I changed rear set and front forks idraulic to have more in criticals situations.not only on tracks,'cause I love extremes inclines and strongs brakes.. Than when I decide to pot on radials brakes calipers,first idea was changed assial brakes attacs with radials but the price was very hier rispect change all front forks with r1 set: you know that who ride in sbk nationals championships, do the change without use the stock unity,so you buy a second hand new one!! I worked like P.T.(my job..)with puccetti racing team for 2 seasons so find stuff was very easy.. Now my fz1 original fork set,with ohlins idraulic,is semi new and unused and I'm so afraid for the dinstance because was a very nice stuff for you.. with calipers and brembo SA pads too... Anyway,greats compliments!!! Steering plates are wonderful!!
 
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Can't! Must go to Alaska THIS year. I just gotta do it therefore the forks will stay on the slow road. It works pretty good, AK has been on the slow road since 2009 and now I'm in the home stretch or at least I'm coming out of the curve and can see the home stretch!
 
According to the site:

There custom made to order.
We only will do 1" or 2" extensions.
They simply slide over the fork tube and bolt into place.
They are machined to perfection with very high tolerances.
These have a 50mm ID that fits most forks like the GSXR 750
TL 1000s and the R1. If you need something custom just contact us.
Click to expand...

I was wondering if they needed to be attached to the fork tube or if the pressure between the two triples would suffice. The advantage to these guys is you can pay for the part a little bit at a time.
 
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