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Discussion Starter #1
Hello all!


I recently bought a pair of R1 2002-2003 fork legs for the Warrior fork mod. These R1 fork legs came without front axle and fasteners so all I got right now is a set of R1 02/03 fork legs and a R1 02/03 front fender. Need to order some additional parts to be able to mount the R1 fork to my Warrior. I´m trying to gather a parts list, searched a lot but haven´t been able to fully verify what parts that I need for the install. Don´t know how many miles the R1 fork have so I´m also getting the parts needed to do a rebuild of the fork.


Can someone help verify what parts I need? Made a list of parts (I thinkis needed):


Edit1: Got some answers. Updated the parts below.


Edit2: Found some more information on the rebuild, updated parts for rebuild.


R1 02/03 front axle parts


Axle, flange boltneeded (also the fork pinch bolts, butI got those). Cap is optional. Warrior wheel collars are reused.


R1 02/03 front axle 2C0-25181-00-00 (AXLE, WHEEL) x1 (needed)


R1 02/03 front axle bolt 90105-14002-00 (BOLT, FLANGE) x1 (needed)


R1 02/03 front axle cap 5PW-25188-00-00 (CAP) x1 (optional)


R1 02/03 wheel collars 90105-14002-00 (COLLAR, WHEEL) x2 (not needed)





R1 02/03 Front fender fasterners


All fasteners needed, brake hose holders seems not to be needed. Not sure if the r1 02/03 brake hose holders work with the Warrior hoses.


R1 02/03 fender bolt 90111-06043-00 (BOLT) x4 (needed)


R1 02/03 fender grommet 90480-12072-00 (GROMMET) x6 (needed)


R1 02/03 fender collar 90387-06159-00 (COLLAR) x6 (needed)


R1 02/03 fender bolt back 90111-06030-00 (BOLT) x2 (needed)


R1 02/03 fender nut back 95707-06500-00 (NUT) x2 (needed)


R1 02/03 brake hose holder 5PW-25875-00-00 (HOLDER, BRAKE HOSE 1) x1 (optional?)


R1 02/03 brake hose holder 5PW-25876-00-00 (HOLDER, BRAKE HOSE 2) x1 (optional?)





R1 02/03 Fork rebuild


Checked the R1 02/03 service manual, oil seal, dust seal and bottom gasket should be replaced when disassembled. Also found some more information on r1-forums.com. The bushings (METAL, SLIDE) usually should be replaced.


R1 02/03 oil seal 5PW-23145-00-00 x2 (always replaced according to manual)


R1 02/03 dust seal 4PU-23144-00-00 x2 (always replaced according to manual)


R1 02/03 bottom gasket 2K8-23158-L0-00 x2 (always replaced according to manual)


R1 02/03 metal bushings/sliders 5PW-23125-00-00 (METAL, SLIDE 1) x2 (recommended to replace)


R1 02/03 oil seal clip 4V4-23153-L0-00(RING,SNAP) x2 (replaced if worn)


R1 02/03 washer 5PW-23146-00-00(WASHER, OIL SEAL) x2 (replaced if worn)


R1 02/03 upper cap o-ring 3XJ-23147-L0-00 x2 (replaced if worn)









Hope you guys can help me out, all help appreciated.



Best,


/Lars
 

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Discussion Starter #3
The R1 fork is possible to adjust more than the Warrior fork. And (hopefully) the R1 fork will perform better on the street than the original. Also, the R1 fender mounted on the Warrior looks cool!
 

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You can use the Warrior wheel spacers (collars) with the Warrior wheel.


You need the R1 axle & pinch bolts + the flange bolt the cap is optional,


You need all the fender mounting hardware.


Can't say about the fork seals etc, have not had to rebuild mine.
 

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Discussion Starter #9
Thanks Churchkey, that´s exactly what I needed to know!
Did you replace your springs? Also, looking at your picture, the R1 02/03 brake hose holders aren´t needed at all?


/Lars
 

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Edit-double post
 

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I thought I would give the stock R1springs a try & they worked well for me. There is considerably more shock control over the spring with the R1 valving. Iran with the stock Warrior front end spring adjusters all the way down trying to reduce the "wallow" effect of the stock front forks.


I ended with the R1 spring adjusters about 1/2 way down.


Suggest comp & damp adjustments at 5 clicks out on each one.


The lower brake line brackets went in the trash can when the SS lines were installed years ago.
 

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Like Churchkey I also used the standard springs, although I used 99 R1 forks. These were 20% stiffer than the Warrior springs, 0.75kg as opposed to 0.6kg,and I find them perfect for my weight which is about 200 pounds. I also found the optimum damping was 5 clicks out on both compression and rebound damping. I had to set the preload to 9 rings showing to get the correct static sag, the standard setting being 8 rings showing. Good luck. You will like the forks.
 

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Discussion Starter #13
I´m staying with the stock R1 02/03 springs, willprobably work good for me. Looks like we are going to tear the R1 fork legs appart tomorrow, will be interesting how far we can go without all the special tools. Then I will order parts depending how good/bad the internals look.


Thanks for the tip guys!


Cheers!
 

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Good luck with this Manax!!! I have a set of 01 R1 forks, an R1Fender now painted Indigo and all the internal parts needed for a rebuild so we shall be doing it together:}:} I am putting the R1 lowers inthe Warrior uppers and then putting on the chrome covers. Fun project..........I hope:}:} Good luck:}
 

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Discussion Starter #15
I had the legs apart and they looked ok inside, so I just changed the oil (though I didn´t remove the damper rods). Put them back togheter and installed them on my Warrior. Currently playing around with different suspension settings.



You will need a extra set of hands when tearing them apart. We had to make a tool to compress the spacer, that alsoallow you (at the same time as compressing the spacer) to access the nut covered by the spacer. I also had an old R1 triple tree (just to hold the legs).


Let me know If I can help out in anyway. Got the servicemanuals for the R1 if you need.





/Lars
 

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Discussion Starter #18
Thank you Mdfdwarrior. Btw, I must say, you got a really nice bike there! Those rims are freakin cool!



Off topic - Must ask, did you feel a lot of difference in handling with the 240 and the Carrozzeria rims? Planning to do the 240 mod on the stock rims just to know if I like the handling, before getting wilder rims like Carrozzeria or RC. End off topic.


Best,


/Lars
 

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What a great mod:} I've found that I need the preload cranked as far down as poss and now have about 38mm of sag. Rides really softly yet doesn't dive as much at lights etc. The rebound and compression are each at 5 out awaiting a good ride to see what I really need. A good trick for checking sag is to use a small zip-tie around the forks so you can check the travel since it will be pushed down the fork as you sit on it. Also, if you leave it on for a ride, it will tell you how much of the travel is being used.





 

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fcwarrior said:
What a great mod:} I've found that I need the preload cranked as far down as poss and now have about 38mm of sag....

Jeez mate. How much do you weigh
I was only getting 25mm of sag with the standard 8 rings showing. This was on 99 R1 forks and I weigh about 200 lbs. I adjusted my preload to 9 rings showing to get about 35mm of sag.
 
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