FJ09 Adventure/Rally build

Discussion in 'Some Assembly Required' started by Garlockness, Apr 29, 2021.

  1. Garlockness

    Garlockness Adventurer

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    Hello all, thought id document this here for others who really strongly dislike the fj09... and bought one anyways to build it into a race ready adventure bike ! OR just some who are more curious to make your fj09 better for off highway adventures!

    2019: couldnt wait any longer for tenere 700 to show up. bought a brand new 2015 yamaha fj09, was never uncrated, sat in a yami warehouse for years, got a good deal! Front wheel swap: 1999 bmw f650 funduro wheel, 17mm axle same as our bikes, galfer rotor, spacers to push rotor out , single caliper, worked great! Just moved the fender up a hole no problems!

    Doesnt hit radiator
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    #1
  2. Garlockness

    Garlockness Adventurer

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    Step 2 , threw a knobby on the rear! DB03085A-84C2-4620-8264-201320DC62AF.jpeg
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    this was kinda fun! But anyone who owns an fj, can attest to its terrible stock suspension! Ruff onroad, worse offroad!
    #2
  3. Garlockness

    Garlockness Adventurer

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    E07942F1-7C22-4E44-B5F5-60E1994B58DF.jpeg 6C205969-B1EB-4FE3-83DF-721BA37C9871.jpeg

    front suspension im working with some wp 50mm extremes! Stock forks only being 41mm this is a huge upgrade even being so old, but parts and tuning being so easy, a solid choice! Still tracking down brake parts and such
    #3
  4. Garlockness

    Garlockness Adventurer

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    Rear shock not such an easy choice. Ill try to cover this alot. So there obviously isnt much room for reservoirs , and luckily from others posting i learned fast that top mount, sport bike style shocks are the only ones i could squeeze in. After many weeks of looking i settled on a 2019 WP 701 SM shock.
    E773C376-6F5A-4BD8-B1AA-D4D9C5B288A3.jpeg
    here is a comparison of the shocks. Almost laughable.... i actually did laugh. At how cheap yamaha is. And almost cried. This bike is honestly so cheap, im really disappointed with yamaha build quality and dont know if id recommend one. BUT back on track . Plan is get the top mount in, went pretty straight forward , had to do some trimming and stuff but no big deal. Then it was going to be tig weld some mounts on the swing arm for a direct mount suspension, and rid of the linkage. My linkage bushings failed and the bike felt horrible... at 2,000 miles..... big mad. 58B1EEAC-718C-4912-AD31-DD64B7FA1AEF.jpeg
    #4
  5. Garlockness

    Garlockness Adventurer

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    FC2F2DAA-9FDB-4124-87F8-E6A927C51E7A.jpeg
    tig weld ?? Yeah well im still working on getting mine, buddys wouldnt text me back, got impatient and welded up a steel bolt on solution. D6E5BC3C-B351-4296-A927-E659B7B89396.jpeg
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    BIG TIME lift. Seat height is at 37” and front is on stock forks, shock feels amazing, extra travel feels amazing, being able to tune it.... so nice. Tore all abs lines and motor out. Going straight from masters to calipers. Day i got it i unplugged front wheel sensor, so disabled tcs abs. 50D12B4D-2757-4254-917E-2E61DFBFB1F9.jpeg
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    #5
  6. Garlockness

    Garlockness Adventurer

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    Do to the lift exhaust was a victim, as-well as the center stand, AA230140-CD30-4B5D-98AC-7EAA82AB4887.jpeg
    Cut out the center and welded it back in farther up at a different angle.
    #6
  7. AntónioPereira

    AntónioPereira Adventurer

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    #7
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  8. JagLite

    JagLite Long timer Supporter

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    Excellent ! :clap
    #8
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  9. Garlockness

    Garlockness Adventurer

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    Only time ill post a picture of it like this ☠️ Looks like it crashed into a wall haha 879A2712-15FE-402B-A21B-C2BE1D41BB30.jpeg
    About as ugly as it gets haha but no worries, got to throw the new forks on and tried a 21” front. 86B615E7-6ABC-456D-8588-5AAC5BB4AAD5.jpeg
    Thats BETTER!
    #9
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  10. Garlockness

    Garlockness Adventurer

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    Also added a chain roller , will also be adding a chain guide soon 861FB598-5542-4357-94C1-CF8F27265CF0.jpeg
    Its also worth noting, that i had to put a 1/4 spacer underneath the rear tank mount to clear the new shock reservoir from the fuel pump. All plastics and seat seem to still line up fine

    Attached Files:

    #10
  11. Garlockness

    Garlockness Adventurer

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    “FJ09 doesnt have enough ground clearance to be an adventure bike” CDBDBF01-066E-4B52-B567-B04DBCF43970.jpeg
    #11
  12. Garlockness

    Garlockness Adventurer

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    Got the 19” back on to take a look! This is probably the setup ill run initially to set up and tune all the new suspension 6A3FFE2F-2489-420D-8D15-241FFA98678B.jpeg
    #12
  13. Bt10

    Bt10 Long timer

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    Very interesting to me. I feel like I could sit around a campfire and look at the bike for awhile, know what I mean?

    19" looks best to me, probably be fine for the speed I would ride offroad, but curious of the weight. Planning a rad screen or skid plate?

    :lurk
    #13
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  14. Garlockness

    Garlockness Adventurer

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    Thank you, i appreciate that! I definitely do haha
    But yeah at this point id agree. i do plan on both, skid plate is coming up soon on the list, but waiting tell i get the exhaust done!

    weight i wont know tell im done, but it should be right on par or under for a large cc adventure bike, 1190 1290, africa twin, multistrada enduro, ect. As long as it stays under 500 wet, im a happy camper!
    #14
  15. Garlockness

    Garlockness Adventurer

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    Thought id share some of my ideas for it cosmetically, really love 90s dakar/ rally bikes, dual headlight fairings. Kind of a mix of new and retro, will eventually build some auxiliary tanks in the rear, here is one of my original renderings 86E63E8F-6F4C-4330-AAFE-3D2743BCF48D.jpeg
    ..... i couldnt photoshop out the passenger pegs because my gf was in the room, trying to find a replacement for that. The passenger pegs not the gf.
    #15
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  16. Garlockness

    Garlockness Adventurer

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    Been at a stand still trying to decide on options for a front wheel. Obviously all these parts are expensive and i figured theres gotta be a strong, cheaper option! Well it was in my back yard the whole time! I forgot a had an unknown billet hub, turns out to be from a ATK 605! Talon hub, oversized spokes!

    15027369-7A7B-4B68-8EE5-5DEDC4D55EE7.jpeg 12052EC5-D46F-4E5A-B729-1C54446F7893.jpeg 3AEECCDC-BCB1-4FB5-A5E6-A89E0CEC9F4A.jpeg 4E327D0D-0561-4A7F-B4E7-0A5443F0D66D.jpeg
    laced it up to a rim i had laying around! Just waiting on bearing to true it. Should be a great STRONG wheel for testing the bike with! Also as a collector of fun motorcycle things, a vintage talon hub from an atk is pretty rad as-well haha
    #16
  17. draco_1967

    draco_1967 Spoon!

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    Have you thought about finding a swingarm from a 2019+ Tracer? they are 2" longer. You could gain a bit more clearance that way, and balance out the look front to back a little. I like this project. It's bonkers, and awesome!
    #17
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  18. Garlockness

    Garlockness Adventurer

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    I definitely have!! That was the original goal, but im kinda waiting to see how the stock swing arm handles the abuse haha if it goes well thats exactly what ill do! If not ill be building one haha but thanks alot! I appreciate it, more fun stuff coming very soon!
    #18
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  19. Garlockness

    Garlockness Adventurer

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    8F105CF5-5285-44D1-9A14-7475916CCEF7.jpeg
    another rendering with some other design ideas. Really want some extra tanks, fuel range is definitely not where i want it on this bike!
    #19
  20. Garlockness

    Garlockness Adventurer

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    O ring on a step bolt so it doesnt actually put pressure on the carbon, everybody loves nice hardware. 04473816-85D3-4920-A14A-EB50D405EDF5.jpeg
    Spent some time mounting the low fender on the wp 50mm extremes, had an idea, so i bought some 58mm clamps from cj designs, and bent up some simple aluminum flat stock, simple and strong design! Once im sure i wont mount anything else off of them ill trim up the flat stock into a more appealing shape
    #20