An Unholy Union V: DRZ forks on an Airhead

Discussion in 'Airheads' started by Ras Thurlo, Jun 28, 2014.

  1. One Less Harley

    One Less Harley OH.THAT'S GONNA HURT

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    Motopsychoman-I noticed what I would assume to be witness marks on the bolts..not the bolt and surface it attaches to....that doesn't let you know if the bolt has loosened...or is it just don't to let you know that it was torqued upon assembly..
  2. Motopsychoman

    Motopsychoman Not a total poseur Supporter

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    That it was torqued and checked off my list. I currently have about 65 inspection items on my list. I haven't yet made it to the aircraft-style plastic paint that goes across the bolt and base and cracks when it has moved. Each major "expedition" I change the color.

    Notice the safety wire on the caliper bolts. I've torqued those bolts multiple times now and they've worked loose twice. I like safety wire. I find that properly torqued fasteners generally don't work loose. There have been a few exceptions...
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  3. quokka

    quokka Adventurer

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    I don't want to hijack this wonderful thread but I do have a DRZ/GS project and related question. Perhaps the collected wisdom here could look at my post
    1989 R100GS Wheel Bearing Question
  4. OncoGSPD

    OncoGSPD Adventurer

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    @Phreaky Phil, do you remember which pistonkit you ordered ? Could that have been this one ?

    @Does anyone in NL has any experience with sleeving the 13mm brakecylinder of a 91-96 GS to a 12mm ?

    Thanks !
    Onco
  5. KaaJa

    KaaJa Been here awhile

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    I got 15mm cylinder resleeved to 12mm, was cheaper to do than 13mm, they could use thicker sleeve. Piston is g/s one from motobins.
    It works really nice with f800 caliper.
  6. OncoGSPD

    OncoGSPD Adventurer

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    @KaaJa , I have first have to find a company in Holland which could do the trick. I asked ( brinkrevisie.nl ) tonight.

    What kind of 15mm cylinder are you using ? Largest I can find that might fit my current handlebar housing (R100GS >91) is this 14mm one.

    The piston should be this one I presume.

    I have a 13mm Mastercylinder on a F650 caliper. Breaks alright, but lacks a bit of feel.
  7. PaulRS

    PaulRS Dutch fool

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    12 mm pumps are still available.
    P/n 32 72 2 302 367

    Not cheap, but that 12 mm piston and re sleeving your pump will also cost a bit.

    Paul.
  8. OncoGSPD

    OncoGSPD Adventurer

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    Thanks Paul, but will my >91 switches fit this handlebar unit ?
  9. PaulRS

    PaulRS Dutch fool

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    The pump is a separate unit, bolted to the handlebar unit with 2 allan (imbus in Dutch) screws/bolts.

    Below the reservoir, where the hydraulic line comes out, you can see them.
    Unscrew and the pump pulls out as a unit.

    Or check the 2V section on the Dutch GS forum, lots of info there.

    Paul.
  10. OncoGSPD

    OncoGSPD Adventurer

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  11. PaulRS

    PaulRS Dutch fool

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    Ok, I see.

    You got the newer switches with the left and right 'flippers' for the turn indicators, like the R1100.
    I forgot they used them on the latest airheads already.

    Back to the drawing board then, I guess.

    Paul.
  12. KaaJa

    KaaJa Been here awhile

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    Cylinder is from r100r with twin discs, found it on german ebay.
    Piston is same as in your link.
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  13. red bud

    red bud alky w/motorcycle problem Supporter

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    will dr forks work on a r100r??
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  14. Motopsychoman

    Motopsychoman Not a total poseur Supporter

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    Folks, I have a number of old DRZ/RM parts that @Guoseph generously cleaned out of his garage. Before I offer them up on the Good Karma-Free Stuff thread, I thought I'd offer them up here as most could be useful for a DRZ conversion.

    These are free, but MUST be picked up in the SF Bay Area (or I could probably drop them off nearby if I'm out and about). I'm not shipping these anywhere:

    21" x 1.60" RM250 front wheel.
    IMG_20200821_132430862.jpg This is the earlier, narrower hub with the 50mm bearing spacer (DRZ and later RM hubs had a 70mm spacer). No dents in the rim and no frozen spokes. I got it spinning pretty straight but it could benefit from some more spoke adjustment. Will be needing bearings and seals.

    250mm RM/DRZ front rotor.
    IMG_20200821_132515992.jpg
    No measurable wear and appears straight.

    GONE DRZ00/RM250 caliper, hose and RM250 master cylinder.
    Master cylinder appears to be 11mm.

    GONE DRZ/RM front brake pads (new). All Balls steering head bearing set fits various Kawasaki and Suzuki models.

    PM me if you want any of these items and can pick them up. I'll probably post them over on the Free Stuff thread tomorrow.

    Attached Files:

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  15. The Patagonia Kid

    The Patagonia Kid gnarly adventurer

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    Will follow advice on protecting parts. :-)
    They should ... now are you using the DRZ triple clamp or getting one from Prutser?
    If you use Prutser's triple and DRZ forks the stock R100R 18" wheel should fit right in the center of the forks allowing the use of the original wheel / rotor. You will also need a BMW 1200 GS caliper and the bracket to hold it + proper axle (use BMW 800GS) :-)
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  16. red bud

    red bud alky w/motorcycle problem Supporter

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    not doing anything yet, starting to rap my mind around the idea, current forks definitely need improvement
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  17. The Patagonia Kid

    The Patagonia Kid gnarly adventurer

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    Let the fun begin ...
    If anybody needs the part numbers for some of the items will be in the attached pictures.
    Original Suzuki brake line guides, Tusk fork neoprene protection, BMW R9t reflectors and SKF bearings. :-) Double rotor set up 15.jpg Double rotor set up 16.jpg Double rotor set up 17.jpg Double rotor set up 18.jpg
  18. The Patagonia Kid

    The Patagonia Kid gnarly adventurer

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    WIP ...
    New bearings installed and also weight comparison.
    New DRZ set up with double caliper tips the scale at 35 pounds
    Old original stock GS with original 2 piston caliper: 30 pounds ... not a high tech scale but does the job! :y0!
    By the way the stock GS front suspension will be up for sale soon in the flea market or eBay.
    Double rotor set up 19.jpg Double rotor set up 20.jpg Double rotor set up 21.jpg
  19. The Patagonia Kid

    The Patagonia Kid gnarly adventurer

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    By Sunday if things go as planned should be on the road again. :clap
    Double rotor set up 22.jpg Double rotor set up 24.jpg
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  20. The Patagonia Kid

    The Patagonia Kid gnarly adventurer

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    Making progress ... not sure if will route the brake lines from inside the forks or outside. :hmmmmm
    Because I installed a 30 mm riser swapping to the lower handle bar was the proper thing to do, otherwise cables would not be long enough.
    Will start testing / riding with the 18" wheel ...
    Double rotor set up 25.jpg