Help with 2003 forks

[HotRodZilla]

So, my brother-in-law, Mike, has a 2003 FJR that he bought used. It has had fork seal issues since not long after he bought it. He took them to a local mechanic who is known for doing good work and got the seals replaced.

The owner told Mike that someone scratched up the "inner tubes" and the seals will not last long. Sure enough, 6 months later he is leaking fluid again. Now, I don't know much about FJR forks. They intimidate me. I've only seen one set taken apart and I don't remember any "inner tubes" but I'm thinking he's referring to the smaller diameter tubes. He told Mike that they were too damaged to properly repair and Mike would have to replace them but that he's screwed because parts are no longer made for '03 bikes. I'm under the impression he cleaned them up and put them all back together, just to have another leak spring in 6 months.

So, a few questions:

>I have heard of gouged tubes being an issue. Is it true that they are not repairable, or can he send them off to Traxion or someone like that and have them fixed?

>If he cannot, is there any difference between the way any of the forks are built or specced(sp?) from 2003 to 2013? Basically, can he use internals from any year? I know there are two bushings in GenI bikes and 3 in later models. I'm just wondering if the tubes will fit, regardless of year. Also, is there any reason he could not put a set of 2004 forks on there as long as he got them with the wheel? I'm pretty sure all the triple trees are the same, so any set of FJR forks should fit. Right?

If different year tubes will work, or he can just change out the entire set for a newer, non-cash model, does anyone have a set they want to sell, or have a good source? He's under the impression he's screwed, and I know better.

Any help is appreciated. Thanks!!

[wheatonFJR]

Gixxerjasen to the service desk!

EDIT: Seriously though, I hope that an doable solution can be found with a 2004 or later set of fork tubes. I'm sure they are different, but seems like parts could be found that could be made to work.

[gixxerjasen]

Gixxerjasen to the service desk!

Cracks knuckles, takes a swig of his drink to get ready to type

Actually, I don't know a darn thing about interchangeability of forks between years, so hopefully someone else chimes in.

There IS something here I CAN speak on with some authority though. I too was told that my inner tubes were too scratched up to use by my local dealer who came highly recommended.

I understand your friend is hard up and looking for a cheap route out. NOT NOT order any Chinese produced fork inners for this project. I thought I struck gold, because no one had one in stock anywhere in the country and here was a company shipping some from China selling them by the pair for dirt cheap. I thought "How hard can it be to make a metal tube?"

I packed everything up and sent it off to Traxxion as I didn't trust myself at that point in time. Apparently Traxxion inspected everything and ran some quality tests against my shiny new inners and determined the production quality to be so poor and out of tolerance that they personally classified them as "Bent." Hundred and some bucks thrown away. I ended up ordering one from an online Yamaha dealer and they took the slow boat from Japan and finally arrived and Traxxion declared them as perfect.

That's my input, DO NOT answer the siren's call of inexpensive parts from China for this type of thing.

[raYzerman]

Score marks or pitting can wreck seals, as well as dried on bug guts. You sorta need to stick with Gen1 tubes as they are unique on the lower end with the Oil Lock Piece. You have to keep the Gen1 lowers because of the unique axle/wheel setup. However, a certain old fart recently did same... FJRay to the white courtesy phone. I don't know what he did in the end.
I believe you can use Gen2 or Gen3A fork tubes with that Gen's Oil Lock Piece, don't really see why not. Bushings and seals are the same (no middle bushing on Gen1). Certainly you could buy Gen2/3 forks complete as long as you got the wheels, brakes, ABS adapter, etc. but would have to deal with linked brakes by tying in the lower right piston to the front brakes (ie. adapter hose).
Jasen's tubes were alledgedly scored, but I'm not sure where or how bad. Yes some can be refurbed with crocus cloth, filing off sharp edges and polishing, but that depends on how bad it is. Sharp edges and dried on dirt will eventually ruin a fork seal lip.
I'll keep my eyes peeled fer tubes 'n such....

[Auburn]

AJ, I have a set of 2005 forks, that will work. They are left over from ChazGlenn when we had to buy a set to get cartridge to repair his 2008. The tubes appear to be straight and not scratched.

You have a PM

[HotRodZilla]

Man, you guys rock! AuburnFJR has shipped a set of fork tubes. Should work perfectly. I honestly don't know what I would do if I didn't know about these places. I owe a lot of people a lot of beers. Hahaha!!

My BIL is gonna crap his pants, seeing how he was told there was no way to fix his bike. Lol. I knew that was BS as soon as I heard it.

Thanks again!!

[BkerChuck]

Zilla, Sorry I didn't see this thread earlier. Front forks on a bike are quite similar to the hydraulic cylinders used on cranes, log splitters, and other devices with hydraulic cylinders. In other words, if you have a hydraulic cylinder repair shop nearby there is always the possibility they could have those inner fork tubes industrial hard chrome plated then polished back to the correct OD. It wouldn't be super cheap to do it but it can be done. Obviously having a set sent to you as what has happened is awesome but I want to make folks aware that short of being bent or horribly out of round they can be repaired.

[raYzerman]

Zillla, you can't buy enough beer, so don't sweat it, but keep trying though, a lot of guys I know are thirsty bastages.

[HotRodZilla]

Zilla, Sorry I didn't see this thread earlier. Front forks on a bike are quite similar to the hydraulic cylinders used on cranes, log splitters, and other devices with hydraulic cylinders. In other words, if you have a hydraulic cylinder repair shop nearby there is always the possibility they could have those inner fork tubes industrial hard chrome plated then polished back to the correct OD. It wouldn't be super cheap to do it but it can be done. Obviously having a set sent to you as what has happened is awesome but I want to make folks aware that short of being bent or horribly out of round they can be repaired.

THAT is good info. I would have never thought of that!

[HotRodZilla]

Zillla, you can't buy enough beer, so don't sweat it, but keep trying though, a lot of guys I know are thirsty bastages.

Meh, a keg of Shiner Bock is pretty cheap. I know you clowns may try to drink it all, but I also know you will all have a hangover from Hell so know to go kind of easy...I hope! Hahahahaha!

Though...What to you danged Canadians drink? Molson Ice?

[wheatonFJR]

Coors Light.

[FJRoss]

Coors Light.

One thing about Coors Light is that it doesn't change much when you recycle it. Just a bit warmer.

[Hppants]

Ok - flag on the play.

I can tolerate a lot. I can take oil threads over and over. I can watch people lie we..... tell stories about how many miles they get on their tires. I may never get the image of Barry with the Alpaca out of my mind, but surely I’ll manage.

But I cannot allow Coors Light to be called “beer”. Byproduct of a horse bladder? Absolutely. But beer? No.

[raYzerman]

PPP = Percolated Pony Piss.... nothing a good Scotch or Tequila can't fix.

[HotRodZilla]

PPP = Percolated Pony Piss.... nothing a good Scotch or Tequila can't fix.

So, you're saying if you mix a good Scotch or Tequila with Coors Light, it's ok to drink? Something tells me that in top of tasting like an unwashed ass, that's also gonna hurt later on.

Bud Light would be even worse. Lol.

[blind squirrel]

PPP = Percolated Pony Piss.... nothing a good Scotch or Tequila can't fix.

So, you're saying if you mix a good Scotch or Tequila with Coors Light, it's ok to drink? Something tells me that in top of tasting like an unwashed ass, that's also gonna hurt later on.

Bud Light would be even worse. Lol.

You know what an unwashed ass tastes like?!?

[raYzerman]

I am an ass.... no mixing... OMG!! Bud Light is the closest thing there is to plain water...

[Intech]

The proper way to mix good scotch or tequila with light beer is:
1. Pour the booze in a glass.
2. Open the light beer.
3. Go to the sink and pour the light beer down the drain.
4. Go back and enjoy your booze.

Note: this recipe works with good bourbon too.

[Intech]

Deleted double post

[Hppants]

^^^^^ Ya know, that just might make a good T-shirt!!!!

(Sorry AJ for jacking up your thread. I'm glad your BIL's fork situation is on its way. Truthfully, you knew this was a no brainer. You can't kill a gen 1 FJR, and you sure as hell can't kill it with a leaking fork seal. We shit stirrers might as well have some fun, right?)