Bandit 400 Project/Restoration

[HD]

So I have bought myself a 1991 Bandit 400 from chillyman0 of here.

The plan is to get it working by my birthday/test at the beginning of December. Going to be a struggle with starting my A-Levels and all but every moment other than homework and shit will be spent on it

Plan is as follows:

Strip bike completely
Do piston rings and if anything else is nasty inside there.
New brake master cylinder/calliper seals and brake pads.
While that is all being done, the frame, swingarm and wheels (possibly fork bottoms) are being powdercoated.
New front tyre.
New front seat (hopefully both so they will be matching)
Laquer and touch up the current fairings until early next year when I can get it sprayed.
New fork seals
Sort out clocks
Fix speedo
New battery
New rectifier
New rear disc

And I think that is about it.

So yesterday the bike arrived with a guy called Alan who I found on Shiply. Really a great guy and had no complaints. Had a good chinwag with him and seems a decent, reliable guy. Basically on Shiply, if you didn't know. You enter an item, a pickup and delivery address and different couriers bid on the service and you pick the best one. There is a feedback scheme so the lowest price may have no feedback so could be a bid dodgy...

On there he is called southcoastdeliveries and VERY highly recommend him.

So yeah, the bike arrived and I whacked it straight into the garage. Bit hard to push it with the front brakes stuck on a bit

Was so excited that I forgot to take a photo but it was soon stripped a bit so I could have a quick look around.

Chain came straight off and put it in a bowl and put some 2 stroke oil on it and scrubbed it on with a paintbrush. Then decided to drain the oil so it soaked in it as it was rusty.

The oil was black but it was very good, no bits or silky appearance and you can almost see through it.

https://i1126.photobucket.com/albums/l618/HDrayton7/Suzuki%20Bandit%20400%20Project/IMAG0346.jpg

Sump nut was bloody tight though and I ended up mangling it so that is on the list, too!

Then thought I would see what the green taped wire is doing going into the left side of the engine. I though maybe generator or something but when I took it off some more oil came out, so just aswell I drained it before

https://i1126.photobucket.com/albums/l618/HDrayton7/Suzuki%20Bandit%20400%20Project/IMAG0347.jpg

When it was off, I forgot to take photos though But the wire is broken and I am thinking is the speedo there? Or is it down at the front wheel?

Front discs are also rusted but are very good condition, no lumps or bumps and even the rust is smooth so will rub it over with some 1200 and a bit of wd and leave it til I start rebuilding the bike.

https://i1126.photobucket.com/albums/l618/HDrayton7/Suzuki%20Bandit%20400%20Project/IMAG0348.jpg

And the rear disc isn't rusty but is proper bad Loads of ridges which you can just make out in the pic:

https://i1126.photobucket.com/albums/l618/HDrayton7/Suzuki%20Bandit%20400%20Project/IMAG0349.jpg

And thats about as far as I got yesterday to be honest.

Going up there again in a bit to whip off the clocks, bars etc., front fender, hugger, airbox and maybe a few other easy bits like rear light etc.

But I'm gonna leave major things like engine/carbs/main electrics til when my fathers down with me as I am just a novice atm But that is the aim of this project, to learn!

Sorry about forgetting to take pics, I'll try... promise

More updates to come frequently, hopefully, and this will be a fairly quick project. Like I said I want to get it done in 3 months but may run over a bit so I maybe cycling everywhere again
____________________
Rusty '02 Vito Camper + CBR600F3

[P.]

I'll be watching this.

Also rate Alan from shiply

[Pete.]

Before you tear down the engine do a leakdown test. You might have no reason to pull it apart, unless you know already that there is.

I have a set of refurbished carbs for a Bandit 4 BTW. bught them off a guy on Greybike and never used them.
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[HD]

[Pete.]

I paid £27 for em so you could have them for £25.

A leakdown is similar to compression, but it measures leakage not just cylinder pressure. You use two gauges with a restrictor in between. The leakdown is expressed as the percentage difference between the two guage pressures. The other benefit of leakdown testing is that you can actually hear where the leak is by listening at the intake or exhaust.

https://en.wikipedia.org/wiki/Leak-down_tester
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[HD]

Nothing major today done really. Just undone like 40 thousands nuts and bolts

There is now nothing on the back end, no bars, no exhaust, no front fender, no peg hangar on the right side, no passenger pegs, no brakes and I think thats about it!

Hardest thing? Undoing the front fender, my god! The bolts are ontop and they have nuts so you have to go under the tyre with a spanner in about a 1cm gap.

I did a bit of a boo boo aswell On the throttle side switchgear, one of the bolts wouldn't come out cos it was rounded already and I couldnt cut a slit in so I drilled it out. Apart from I didn't. I wasn't drilling square so it came out of the side and it was absolute murder. I should have just slid it off the bars

How it stands currently:

https://i1126.photobucket.com/albums/l618/HDrayton7/Suzuki%20Bandit%20400%20Project/IMAG0357.jpg
____________________
Rusty '02 Vito Camper + CBR600F3

[alun111]

that wire you mention is for the crank sensor (or commonly known as the pulser coil, or pickup coil). It tells the cdi when to spark. Get it repaired with some soldering and heat shrink.
____________________
Summer: '00 Honda CB600F Hornet
Winter: '93 Suzuki GSF 400 Bandit VP Variable Valve
Past Bikes: Lifan LF100-5 Lifan LF125-A Honda C70

[Nope.]

Cool project. Watching this one!

I do belive the engine in this is a de-tuned version of the engine in my gixxer.

Any chance you could take a picture of the carbs and put them up for me?
____________________
2011 XT660Z Ténéré - 2003 YZR-R1 5PW (In Build)

[HD]

[Nope.]

[HD]

Thanks for the heads up

It will have to be tomorrow now as it is getting dark but I will get both views for you cos I'm so nice

Don't know if they are Mikuni's or not though...
____________________
Rusty '02 Vito Camper + CBR600F3

[Nope.]

[HD]

Ah okay, that would be great

Seeing we are taking pics of carbs, can you grab a picture of the ones you have please Pete.

Just to confirm they are the same. Are they fully functioning? If so, I will probably have them but I'll see what sort of dosh I have as since buying this I seem to have no fucking money

Hopefully I should have everything out of the frame tomorrow as father is coming down to help me get rid of the engine and electrics.

Update(s) to follow
____________________
Rusty '02 Vito Camper + CBR600F3

[HD]

[alun111]

No problem. Any more questions feel free to pm me. My bandit's my main form of transport at the moment as the hornet's off the road. Had it for just over 4 years now.

I'll be watching!
____________________
Summer: '00 Honda CB600F Hornet
Winter: '93 Suzuki GSF 400 Bandit VP Variable Valve
Past Bikes: Lifan LF100-5 Lifan LF125-A Honda C70

[Pete.]

I do believe the Bandit runs a bank of four individual carbs but the Gixxer runs a split pair of two or something daft. I'll put up a Photo of mine anyhoo.
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[HD]

So was down the garage with father today and managed to get the rest of the electrics off and the engine out. Nothing major to report really.

Everything was so simple. Think I could have done it myself tbh but nice to have that help if I needed it. As my dad said, "If you can build a Derbi, you can build anything" Honestly, though, you cannot compare how simple everything on this bike is.

Just the forks and front wheel and the shock/linkage to come off now and its ready for powdercoating next week some time hopefully.

In the mean time, the carbs are gonna be stripped and the engine and maybe the brakes to see what is going on and refresh it all up a bit.

As the bike is atm:

https://i1126.photobucket.com/albums/l618/HDrayton7/Suzuki%20Bandit%20400%20Project/IMAG0368.jpg

Shot of the carbs for computid:

https://i1126.photobucket.com/albums/l618/HDrayton7/Suzuki%20Bandit%20400%20Project/IMAG0360.jpg

https://i1126.photobucket.com/albums/l618/HDrayton7/Suzuki%20Bandit%20400%20Project/IMAG0361.jpg
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Rusty '02 Vito Camper + CBR600F3

[Billing]

those look like the little sods that have problems with the o-rings

The front discs look like EBC prolites, got a set on my VFR, and love them, given them a blue stripe from braking so hard
____________________
'84 TS50X, '91 TZR125, '89 CBR400RR, '91 VFR400R NC30, '98 R1
"Hey copernicus! Why don't you navigate yourself to the back of the line with your feet and stand there with your shit."
BCF Eastern members map here ---> g.co/maps/2tm8b PM me to be added to it!

[Pete.]

Yes they do, mine were re-built with new o-rings etc.

They also have a habit of blocking the choke jets so the bike won't start from cold. The jets are in the stupidest place, right where they will fill up with crap.
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[Nope.]

[Nope.]

Yep. Those are the bastards in question.

Heres a guide to the O-Rings in the GK 73/76 carbs. Im pretty sure they're the same.

https://www.400greybike.com/files/The_Mikuni_carbs_on_GK76a.pdf
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2011 XT660Z Ténéré - 2003 YZR-R1 5PW (In Build)

[HD]

Cheers for the guides computid.

At the moment, the bandit is still as it is in the photo.

But stuck what to do atm. Basically me and the father have had a massive argument and he has told me if I dont sort myself out then I can build my bike myself.

Apparently my attitude stinks and I have no respect

Now thats no major problem but I need to know if he is going to help me or minimum lend me the money cos if not I'm stuck.

Thats another story anyway.

But do you lot reckon, with the aid of youtube, BCF etc., I could replace the seals (maybe pistons) in my brakes, rebuild my forks and maybe my rear shock?

Everything else I think I could do tbh.

Also, if I put some hammerite on the frame and re laquer the fairing/tank do you reckon it should look okayish?

Thanks! Opinions appreciated
____________________
Rusty '02 Vito Camper + CBR600F3

[P.]

[Slacker24seve...]

Cool project.

However, am I the only one terrified at the thought of WD40 on brake discs?
____________________
Triumph Daytona 675 track bike + girlfriend's Honda Hornet 600
Selling a hack/winter bike for less than a grand? PM me.
Banger rallies are ace

[HD]