AUTO
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Chapter V: RZ Fork Swap 01/12/01
The RZ forks are 35mm, the same as the stock Daytona forks. The RZ forks are 30-1/8" long (centre of the axle to the top of the fork), while the stock Daytona forks are 27-7/8" long, so the RZ forks will have to be raised in the triple clamps to keep the stock Daytona steering geometry. It looks now like I will be using the stock Daytona triple clamps, for two reasons. One, the top triple clamp has all the proper mounting holes and brackets for the Daytona clocks (the RZ mounting holes are in different positions), and two because the tapered steering head bearings I just purchased from Pro-Flo fit the Daytona steering stem and not the RZ steering stem. The brakes look to need a rebuild. Luckily, RZ brake parts should be a lot easier to get than RD brake parts, and my RD's brakes were in need of a rebuild anyway. Twice as many calipers in the front end, though - a good thing! I will be documenting the rest of the fork swap here as the story unfolds...
Update 02/02/28
I just picked up an '86 RZ front wheel and disks from eBay. It will need to be powdercoated - the original red was painted over with yellow paint that is chipping off, and I want it to be black to match the rear anyway...The good news is that it is in great shape, and the price was right. All I need now is a front axle, speedo drive, and to refurbish the brake system (caliper rebuilds, steel braided lines) for the swap to be complete. The big parts are now taken care of...
Update 02/05/21Picked up another RZ front wheel off of eBay. This one is in better shape than the one above, it is still the original black colour, and came with useable bearings, speedo drive, axle, and a useable tire. It also came with a set of disks, as well. Pics soon...Update 02/06/22
Did a test fit of the RZ front end. Started by tapping out the old cups for the steering stem bearings and tapping in the new ones for the tapered roller bearing kit. Tapped into place the lower bearing race/bearing onto the stock Daytona steering stem/lower triple clamp, along with dust cap. Greased liberally both cups and both sets of bearings, and lifted into place in the steering head. Put the upper dust cover into place, then nut, and tightened until no play existed but steerer still free to turn.Placed stock Daytona upper triple clamp in place and loosely installed top nut, loosened all triple clamp pinch bolts, and slid RZ fork legs into place. Raised forks approximately two inches in clamps (I will measure this more precisely in the final assembly stage, at this time I just made sure both were raised the exact same amount), and tightened triple clamp pinch bolts. Slid wheel into place, making sure speedo drive and spacers were properly in place, slid axle through, and finger tightened castle nut. Voila! One loosely installed '87 RZ350 front end on a '79 RD400F Daytona Special! I also loosely installed the ATK fork brace, just to see if it will fit properly. Looks like it will. The tire that came on this RZ wheel has very few kilometres on it (it still has 'nubins' intact not far off the centre of the contact patch), but has hardened up somewhat with age. It will make a useable street tire until I can pony up some dough for a newer/stickier Metzeler. I am also going to use the existing wheel bearings, as they seem to be in quite good shape. Next step here is to take apart the forks, see what springs are inside, and rebuild with new springs, bushings and seals if necessary. After that I need a front fender, and to rebuild the RZ calipers and master cylinder and replace the stock lines with steel braided lines.
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Just picked up a set of '87 RZ350 forks, calipers, lever/master cylinder and lines. The twin disk conversion is underway...