Fork Boots and Avons and real brakes oh my... updated

Made some real progress on the front end of the '83: Fork boots (thanks again Wiz) new Progressive Suspension fork springs, EBC floating disc rotor and AVONS! (At both ends.) Still gotta finish rebuilding the caliper and connect it to the stainless steel line that's hanging there...



Rear brake update in that thread...

 

Re: Fork Boots and Avons and real brakes oh my...

Fitz, that is looking real good. I look forward to your comparison of the upgraded brakes and your old ones.

How much do you have tied up in the Avons and why did you choose them?

 

Re: Fork Boots and Avons and real brakes oh my...

Gonna be a sweet ride there.

 

Re: Fork Boots and Avons and real brakes oh my...

Gosh, that picture gives me wood.......

 

Re: Fork Boots and Avons and real brakes oh my...

Where'd you get the gaitors Fitz??

 

Re: Fork Boots and Avons and real brakes oh my...

Very nice! I would like to have your parts list and where you were able to get all of that.

Looks very good!

 

Re: Fork Boots and Avons and real brakes oh my...

You'll love the Avon's -- I used to have the Roadrunners on, and they are spectacular tires! By far my favorite I've ever used. Expensive, and worth it.

 

Re: Fork Boots and Avons and real brakes oh my...

Rob; They're not bad, just under $100 for the front and just over $100 for the rear. chacal carries them for almost exactly the same price I paid. I chose them because of all the tires I considered, Avon and Dunlop are the only ones that do not have a continuous center groove. That feature is important to me because I ride a lot of rain-grooved freeway and they don't want to follow the grooves. My Norton and my '81 XJ both have Dunlops and I've wanted Avons for the better part of 30 years. Now I get to finally run them and I'm excited.

Deadulus; Those are Kawasaki fork boots, PN 49006-1096. In talking with Wiz, they turned out to be the same dimensions top and bottom as the boots on his project Kawi. He got me the part number, I ordered 'em on-line from a Kawi dealer in NC.

Except for the fork boots, pretty much everything else came from chacal. The couple of things that I didn't get from him, he does stock. I got my tires locally (save 1/2 on mounting/balancing that way) and already had a couple of other things before I found XJBikes. Rotor, SS lines, pads & shoes, o-rings, clips, seals, all came from Len.



Note on the brake rotor: It comes with the hub "natural." I had to paint it black. The caliper is painted as well. Rear brake and lever powder-coated.

 

Re: Fork Boots and Avons and real brakes oh my...

Why do a few holes on a rotor make it look 100x better??? Great looking front end!!! I do not know if i can ask, but i will. BIGFITZ How much $$$$ did that cost?

 

Re: Fork Boots and Avons and real brakes oh my...

Brake rotor was $195 from chacal, $10 cheaper than anywhere else I found on line. It's more than a "few holes" it's also a full floating disc. Considering an OEM Yamaha rotor goes for well over $300 IF you can even find them (not for 550s you won't) not only is it an upgrade but a bargain to boot. I'm keeping the original as a spare for my all-stock '81.

If you're talking price for the whole front end project, I haven't added it up, but like I said, chacal stocks pretty much everything but the fork boots.

http://www.xjbikes.com/forums/index.php?threads/14561

 

Re: Fork Boots and Avons and real brakes oh my...

bigfitz52,,,,,can you give us the dimensions on those fork gaitors,,,I'd be very interested in fitting them,,,,Dan

 

Re: Fork Boots and Avons and real brakes oh my...

hmmm now you have me thinking..... i have been really wanting cross drilled rotors or slotted

 

Re: Fork Boots and Avons and real brakes oh my...

BF, that front end is a work of art, beautiful job.
Gregg

 

Re: Fork Boots and Avons and real brakes oh my...

Looking good Fitz - I keep a spreadsheet that adds my purchases - scary number sometimes best left unknown.

Question for you are there advantages to the full floating disk vs a standard disk?

 

Re: Fork Boots and Avons and real brakes oh my...

The gaiters a GREAT.
Please let us know the improvement on brake feel and power.

 

Re: Fork Boots and Avons and real brakes oh my...

Dangit, Fitz that looks awesome. Dunno about the rotors, but I see a set of gaitors and a front-end paint job in my Seca's near future.

 

Re: Fork Boots and Avons and real brakes oh my...

Fitz, just ordered a set of fork boots from my local Honda dealer. It just amazes me how this little shop will roll up their sleeves and find what I need and order it for me...boot set only $20

 

Re: Fork Boots and Avons and real brakes oh my...

Fitz, is the floating rotor the stock offset or are you going to have to use a shim on or machine the caliper a bit?

 

Re: Fork Boots and Avons and real brakes oh my...

STOCK replacement. EBC rocks (as does chacal.) Only mod was painting the hub black and ordering up some black tab washers from our buddy.

I used Duplicolor "Caliper and brake" paint on the rotor and caliper.

Bill; "Floating rotors offer superior mechanical advantage over solid rotor types because when the friction ring gets hot, it expands and grows in diameter. Keep in mind that the outer diameter of the rotor gets much hotter than the hub. This variance in temperature causes a difference in material expansion. The floating rotor design compensates for this variance by allowing room for the friction ring to expand independently of the carrier, dramatically increasing rotor stability, stopping performance, and service life, while also diminishing the possibility of warpage under the most extreme of conditions." (not my words, hence the quotes.)

dburnettesr; They are 35mm ID top, 55mm ID bottom. EXACTLY the right size for the Seca 550's 35mm forks, and the bottom "clips" onto the top ring of the fork legs perfectly. They might stretch OK to 36mm, beyond that you might buckle or distort the top bellows.

The full brake upgrade includes stainless steel lines and a rebuild of both caliper and master cylinder as well; coupled with the new EBC brakes front and rear it oughtta stop quite briskly. The Lockheed front brake on my Norton has me spoiled, it's always been like grabbing a freakin' ROCK, and I can make the 4.10X19 Dunlop howl like a spanked toddler.

 

Re: Fork Boots and Avons and real brakes oh my...

Fitz, what were the specs (diameters) for your forks and what is the Kawi p/n on the boots?

 

Re: Fork Boots and Avons and real brakes oh my...

My forks are 35mm; the boots are 35mm top and 55mm bottom. The Kawi PN is 49006-1096.

 

Re: Fork Boots and Avons and real brakes oh my...

Got the front end all the way back together and reassembled the rear end;



Rolled it outside to snap a couple in the sunlight





The fork boots and the front brake do so much to change the overall look of the bike...



Just a few details to button up; get the carbs right (PO reassembled them out of order, mixed up the float bowls) R&I the alternator cover/brushes, polish the cover; and it'll be road ready. I'm really happy with how it's turning out; it's exceeding my expectations.

 

get it running as good as she looks,,,,yep I like what the fork boots do for the look ,,,,,they won't fit what I was hoping for thanks for the info,,,

fine work,,,what kind of carbs are on these Bigfitz,,,,Dan

 

XJ550s and 900s have Mikunis, the rest have Hitachis.

 

Bigfitz52,

That bike is beautiful man, you did a great job.

XJ700XN's use Mikuni also

Jim

 

whats the matter fitz, you worried someones gonna run your plates! all kidding aside, the bike looks awesome.

 

WOW Fitz, I don't believe it looked that good when it hit the show room floor. Awesome job, just awesome.
Gregg

 

I do like these bikes in darker shades of paint...black especially...my bike, ARACHNE is getting a black paint job. I even ordered a black powder coated ET Wave headlight for it...

 

XJ650 Turbo used Mik's, 1100's too............

 

Fitz. I'll trade you a couple cans of Tim Horton's coffee for the luggage rack! :lol: Seriously though, if you ever see another one like that, please let me know. Or if you know someone that could replicate the rack for a reasonable price I'd be interested.

Rob

PS Bike looks very nice!

 

Hey man, we got a Timmie's on every other corner here too.

That's a GSM SportRack I got off eBay; the guy had a couple and I apparently got the last one. I did let him know that I have a couple of ready buyers if he comes up with any more, and he has my email.

 

Fitz right along the lines of what you have been up to, this week I had a couple of Kenda 671's put on my 750. I searched all over the internet and honestly could not find any bad comments on them so I took the plunge.

Also your de-lamintaing thread got me into gear (thanks) so I replaced both pads and shoes. Used my new Mity-vac and sucked out the 27 year old science project brake fluid. I buttoned it all back together took a ride and holy smokes what a difference new sneakers and pads make.

Really looking forward to your before and after comparison in paticular I would like some feedback on your stainless steel brakes lines will probably tackle those next.

Rob

 

Well Fitz -- I'm reviving this monster because your inbox is full. I am about to pull the trigger on an order with Len for the same front brake upgrade you've got pictured here. I don't necessarily need a new rotor but would you say that this upgrade was a major improvement? I plan on keeping original MC and Caliper.

Love your rides.

Ian

 

big fitz has not been with us for quite some time. as far as a new rotor goes if yours is within the thickness spec and not grooved up or warped there is no need to replace it. You might consider having it turned if you can find a place that can do it.
if you just want to change it for looks then do it

 

I just realized about fitz after digging around -- sad realization. Thanks for the insight XJ550h

Ian

 

I'm glad the thread was bumped up. Wouldn't have seen it (at least tonight, that is) otherwise...

Damn that bike was gorgeous...

Just sayin'...

 

[QUOTE="
Damn that bike was gorgeous...

Just sayin'...[/QUOTE]


Guaranteed it still is!