FJ09 Adventure/Rally build

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

  1. Garlockness

    Garlockness Adventurer

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    had bike night with the boys yesterday, decided id shorten this 1190 adventure muffler to try on the fj09.
    #21
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  2. Foxed101

    Foxed101 Monkeywrench

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    I like this look better. It’s more in keeping with the front. Like what you’re doing!:beer

    #22
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  3. Garlockness

    Garlockness Adventurer

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    Thank you! Appreciate it more to come soon!
    #23
  4. Garlockness

    Garlockness Adventurer

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    Got a front axle sorted, spacers, ect. Finally tossed the blocks and lengthened the center stand haha. Started building a rear tank for adventure rides with a passenger, something i can take on and off easy.
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    #24
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  5. Fakenstein

    Fakenstein Been here awhile

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    this is what its all about. 25% may not work, 25% may need to be done twice, 25% may cost double, but that last 25% is GOLD and works like a charm and may be free! keep going!
    #25
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  6. Garlockness

    Garlockness Adventurer

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    Haha well i hope my percentages are lower! I like to think i know what im doing, it is my job haha. But thank you I appreciate it, and your right its all worth it for the little moments. Should be up in running soon !
    #26
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  7. Garlockness

    Garlockness Adventurer

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    Also a little background, off-road conversions are my niche! It doesnt matter what it is, id prep a moped for off road if i had one! But yeah, if im checking out your vmax at the gas station.... its not what you think haha. a couple of my projects from last year 6BE8FE3F-B873-4041-82F0-D7286705925A.jpeg
    A 1984 k100 i built last year FA5ECC91-8E90-4BE7-AFAC-BE6E6E16A4BB.jpeg
    A 1965 honda s90 with a 2017 yz250f engine, that was fun haha be curious if theres ever been an s90 with more power !
    #27
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  8. Z50R

    Z50R Not lost yet

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    So... the S90 engine has some really cool parts for the CT90/CT110 crowd. The shift drum is interchangeable and allows the bullshit shift pattern to be corrected to the conventional 1 down/4 up. Depending on it being a later production engine, the manual clutch can be a drop in upgrade too. Don’t trash the engine even if it appears to be trash.
    #28
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  9. Garlockness

    Garlockness Adventurer

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    thats interesting! never read to much into it, i have many honda 90s! 3 s90, 1 ct90, 1 s65, but i run lifans in them, most of mine didn't come with an engine sadly! 3CBA4DA6-9D02-4557-8E20-44CD194DAD75.jpeg
    #29
  10. Bt10

    Bt10 Long timer

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    You know you're old when your bikes had the real horizontal Hondas, not the chinese copies! Myself included, Trail 70. :lol3
    #30
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  11. Garlockness

    Garlockness Adventurer

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    haha its hard to want to rebuild the honda engines with a brand new lifan is $300, and 12v! i actually have the original engine for the white one i rebuilt, but when i didn't have the wiring for it, and there was a lifan on the shelf, that was the end of that :lol2
    #31
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  12. Garlockness

    Garlockness Adventurer

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    exhaust done! first ride, its awesome!!! Dirt bike suspension with this engine is top notch fun haha Its very under sprung but to be expected, so ill start figuring out ideal spring rates, also still need foot pegs, front brake, and skid plate!
    #32
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  13. sruss67

    sruss67 Been here awhile Supporter

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    Nice work on the exhaust, great skills to get that done so nicely.
    Very impressive build, love what you have done Garlockness.
    #33
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  14. Garlockness

    Garlockness Adventurer

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    I really appreciate the kind words, look forward to sharing the finish results with you all !
    #34
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  15. Garlockness

    Garlockness Adventurer

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    Well front brake was driving me crazy trying to decide on what i wanted, since i have multiple wheels and cant decide on 300mm or 320mm rotor. So as always got bored and just built an adapter to run a radial caliper on the 300mm rotor, on the 19” and ill make the rotor spacing match on the 21”
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    never did i ever think id build a mount for anything out of angle iron! it works fine haha Ill tig weld some gussets on it, and machine washers to weld on where the caliper has lips on its mounting surface. To locate and get caliper in correct coverage on rotor i just put the new line on, bled it, and zip tied the brake lever down to hold it in place
    #35
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  16. Garlockness

    Garlockness Adventurer

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    but i tightened it all up, and took it out for 20 miles ride, half with a passenger, worked great $10 solution to a couple hundred $$ problem
    #36
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  17. Garlockness

    Garlockness Adventurer

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    Okay so this is attention to all you fj09 riders out there! It would seem you can put stock klr650 foot pegs on your bike! Very comfortable, much bigger !
    You only have to file/grind like a mm off to get it to fit in, its a smidge to wide. 2DA7E7CB-AA58-4CF2-9952-781BFBCB21DE.jpeg
    #37
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  18. Garlockness

    Garlockness Adventurer

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    so now we start getting to the fj09 rally part of it. New front wheel on 63998B1B-7E67-4037-BFB0-0F575F58DD76.jpeg
    #38
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  19. Garlockness

    Garlockness Adventurer

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    I really did not think a high fender would look good, but tried it for fun and im torn! 50% of me thinks it looks awesome, the other half thinks the bike literally looks like an angry bird but i ended up building a mount so i can have both setups 261A20DA-2E7A-4E7E-AB7E-20952468E67F.jpeg
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    #39
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  20. hellotimmutton

    hellotimmutton Been here awhile

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    It's your bike, so at the end of the day its only your opinion that matters, but I like the look of the raised fender
    #40
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