Another GPZ in bits.

[russeleoin]

Hi All. Squishio doing such a good job, I thought I would start a thread and show you all HOW NOT TO RE-COMMISSION A BIKE.

Background; I used to ride a lot in Zim, but since getting married and moving to the UK I have not ridden. Then a job change meant that we no longer needed 2 cars, so I bought a Yamaha YB100. It was in a sad state but I stripped, cleaned, tested and taxed it. Now I love it and am preparing for my licence which was not transferable from Zim. I have sold me old 300E and the YB is my 3 times a week transport to the station. Free to park, £15/yer tax and £14 fuel per month, verse £4.50/day, £198.00 and £60 for the old benz. Anyway, loved my old 55LTD in Zim so when the GPZ came up on Friday ad I went, had a look and bought it. It had been standing for 4 years, but I have time to fix that. All I really want is a nice clean smooth running bike to get going on. I have next to no money to spend (when the wife is around, I have no money to spend).

So I got the bike home last Thursday and started cleaning. I removed tank and fairings etc. Pressured washed it and put it in the garage. Each day I spend a couple of hours working on it.
Today I got it running, smoothly, but definitely only on cylinders 1 and 2. MMMM, burnt my hand when I grabbed the pipe on 2! 3 and 4 were cold. But is did allow me to check a couple of things, Rev counter works, as does the volt meter, most of the electric's. I dont appear to have any water leaks, but there is a sheared bold in the head cover.

Once I have worked out how to attach the pictures properly, I will add them as I started taking after I saw what Squishio was up to.

Regards
Russ

[russeleoin]

Here we go. I had already started work so have no before photo's. I started by pressure washing the whole bike. Then I started on the front wheel. This is after an hour or cleaning.
https://i634.photobucket.com/albums/uu62/russeleoin/Kawasaki%20GPZ400R/P1020507.jpg

other side, not started.
https://i634.photobucket.com/albums/uu62/russeleoin/Kawasaki%20GPZ400R/P1020510.jpg

As it stood yesterday.
https://i634.photobucket.com/albums/uu62/russeleoin/Kawasaki%20GPZ400R/P1020508.jpg

The dreaded Nexxus 4 into 1 and a very poor weld.
https://i634.photobucket.com/albums/uu62/russeleoin/Kawasaki%20GPZ400R/P1020509.jpg

About to pressure wash for the 2nd time( dont worry, I stuffed the carbs)
https://i634.photobucket.com/albums/uu62/russeleoin/Kawasaki%20GPZ400R/P1020513.jpg

Washed.
https://i634.photobucket.com/albums/uu62/russeleoin/Kawasaki%20GPZ400R/P1020514.jpg

Emergency tank to get it running, and run it did.
https://i634.photobucket.com/albums/uu62/russeleoin/Kawasaki%20GPZ400R/P1020517.jpg

Only serious problem, is the bolt holding the cooling pipe to the head has sheared and someone has already tried to drill it out. Oh well, I will have to deal with that later.
https://i634.photobucket.com/albums/uu62/russeleoin/Kawasaki%20GPZ400R/P1020520.jpg

Will carry on going next weekend.
____________________
I love classic merc's but bikes take up less space.
Current ride is a Yamaha YB 100 and I love it! Oooow and now a running GPZ400R!
Next stop, Direct Access hopefully by the end of summer.

[russeleoin]

I carried on with the strip down, cleaning bits on the way. I have taken off the rad and all the cooling pipes for cleaning. Strange thing is that the whole engine and cooling seems to be non-ferrous and yet looking into the head all I can see is rust!. A job for vinegar. With careful drilling and grinding I managed to remove the sheared bolt without any additional damage to the head. I am even able to reuse the existing hole without a problem.

On the down side, I was scammed by a guy on eBay and he has wandered off with £1200. I have been to the police and eBay but and getting very little joy. Everyone using eBay, be aware!

This will probably mean that I cannot keep the bike when it is done, but at least the sale will offset the loss abit.

I will post pictures later today.
____________________
I love classic merc's but bikes take up less space.
Current ride is a Yamaha YB 100 and I love it! Oooow and now a running GPZ400R!
Next stop, Direct Access hopefully by the end of summer.

[Thom]

now it got interesting, come on, tell us who and how did they scam you?
____________________
Current Bike: 1996 Yamaha TRX850 (The Japanese-Ducati One).
Previous Bikes: 1990 Honda NSR125 'Rothmans' (The smoking one), 1990 Suzuki GS500e 'Caf? fighter' (The loud one), 1987 Kawasaki GPX400r (The quick one), 1997 XJ600s Diversion (The reliable one), 2000 Kawasaki ER-5 (The spontaneously combustive one)

[russeleoin]

I was looking to buy an estate car, and a 10 year old benz came up suiting my needs. I paid using MoneyGram( what an idiot) as all the invoice, correspondence etc appeared to come from direct from ebay. I checked on feedback and all I could, but once he had my money he has disappeared. I doubt there ever was a car although there were a good number of high quality pictures, inside and out.

Feel like a real dimwit at the moment but a very good lesson has been learnt. COD only!
____________________
I love classic merc's but bikes take up less space.
Current ride is a Yamaha YB 100 and I love it! Oooow and now a running GPZ400R!
Next stop, Direct Access hopefully by the end of summer.

[russeleoin]

This is where I left it on Sunday
https://i634.photobucket.com/albums/uu62/russeleoin/Kawasaki%20GPZ400R/P1020525.jpg

https://i634.photobucket.com/albums/uu62/russeleoin/Kawasaki%20GPZ400R/P1020524.jpg
I hate tatty wiring
https://i634.photobucket.com/albums/uu62/russeleoin/Kawasaki%20GPZ400R/P1020526.jpg
But I dont need a new one, just tidying the old one.
https://i634.photobucket.com/albums/uu62/russeleoin/Kawasaki%20GPZ400R/P1020527.jpg
The head cover is taking ages to polish
https://i634.photobucket.com/albums/uu62/russeleoin/Kawasaki%20GPZ400R/P1020528.jpg

And now my daily ride.
https://i634.photobucket.com/albums/uu62/russeleoin/Kawasaki%20GPZ400R/P1020530.jpg
https://i634.photobucket.com/albums/uu62/russeleoin/Kawasaki%20GPZ400R/P1020531.jpg[/img]
____________________
I love classic merc's but bikes take up less space.
Current ride is a Yamaha YB 100 and I love it! Oooow and now a running GPZ400R!
Next stop, Direct Access hopefully by the end of summer.

[ms51ves3]

I'm liking your YB100

It's looks in very good condition.

[chadz]

haha good old yb

[russeleoin]

I bought the YB about this time last year, off eBay. Was tired and neglected but they are so easy to work on. I still tinker almost every weekend, polish a spoke or two. She is the perfect runabout, get on and ride, no matter what the weather. I am teaching my 10year old son to ride on her too.
____________________
I love classic merc's but bikes take up less space.
Current ride is a Yamaha YB 100 and I love it! Oooow and now a running GPZ400R!
Next stop, Direct Access hopefully by the end of summer.

[Scouse]

Are you using back to black on the tyres?

[russeleoin]

hi Scouse, nah, I polised the side wall with a little brush and some boot polish( keeping well away from the tread!) about 6 months ago. Now I just give it a very light buff with the brush.
____________________
I love classic merc's but bikes take up less space.
Current ride is a Yamaha YB 100 and I love it! Oooow and now a running GPZ400R!
Next stop, Direct Access hopefully by the end of summer.

[Scouse]

[ms51ves3]

[russeleoin]

Me, YB100 and land speed record on 2 wheels. I can see it now!
____________________
I love classic merc's but bikes take up less space.
Current ride is a Yamaha YB 100 and I love it! Oooow and now a running GPZ400R!
Next stop, Direct Access hopefully by the end of summer.

[russeleoin]

Last night I took the final nut of the 4 into 1, and off came the pipes. Now a question, have any of you seen, or use aluminum pipes. These are defiantly ally, going into a Motad Nexxus. The pipes are in pretty good nic and a bit of wire wool is bringing them up nicely. I will polish with autosol this weekend. The can has been welded in two places, one you cannot see on the underside, and at the neck where it joins the pipes. I have ground down the ugly welds and have started rubbing with wet+dry. I cant afford a new system so will have to make the most of this one. I am pleased that difficult nut came off, well it wasnt the nut but rather the clamp. I used a bearing puller to get it off. No damage so I am happy. I have taken some pictures so will post them when I get home tonight. I will clean the carbs and finish the wiring this weekend, then it is not too much longer before i put it back on the road.
____________________
I love classic merc's but bikes take up less space.
Current ride is a Yamaha YB 100 and I love it! Oooow and now a running GPZ400R!
Next stop, Direct Access hopefully by the end of summer.

[russeleoin]

I am telling you these pipes are ally
https://i634.photobucket.com/albums/uu62/russeleoin/P1020532.jpg
If you have a look at the early pictures you will see how ugly this weld was. I ground it down and will finish it with wet&dry. It wont be perfect but will have to do.
https://i634.photobucket.com/albums/uu62/russeleoin/P1020533.jpg
This one you cant see when it is on the bike.
https://i634.photobucket.com/albums/uu62/russeleoin/P1020534.jpg
The offending stud was 2nd exhast port from the left in the picturtes. It will be completely cleaned then I will smear copper grease over all of them. That will prevent the carboning up in future and make future removal easy.
https://i634.photobucket.com/albums/uu62/russeleoin/P1020535.jpg
____________________
I love classic merc's but bikes take up less space.
Current ride is a Yamaha YB 100 and I love it! Oooow and now a running GPZ400R!
Next stop, Direct Access hopefully by the end of summer.

[michaelnabbi]

they might look like ally but i think you will find they are aluminised steel a mix of ally and steel used alot on car exhausts does not corrode as fast as mild steel but is alot cheeper than stainless
____________________
the faster you go the harder you fall !! you have been warned

[russeleoin]

I have been working(promise) however my time has been limited to an hour or so when I can squeeze it in. I have taken some more pictures and will post them this evening.

Work that has been done:
1.Frame touched up where paint had flaked off.
2.Most of the metal mounting brackets(seat/tank-ignitor-fan-horn etc have been resprayed. Stuck with black for ease of completion.
3.Head cover back on, rad in, horns on, rear mudguard-off-cleaned and back on.
4.Wiring loom off-cleaned-joints resoldered and generally tidied up and back on.
5.Foot pegs off cleaned, greased and back on.
6.Pipes cleaned new gaskets and back on.
7.Key switch fitted with correct length bolts.
8.Rear break peddle and assembly removed, cleaned and back on.

Anyway, so I had a couple of hours yesterday and I thought I would see if i could get it started. So I fitted a new oil filter and filled it with oil. Tightened all the coolant pipes and filled with coolant. Rigged my temp tank and I was ready to go. Jumping from the car battery as mine is dead, all looked well, oil, stand and neutral light on! Press the starter and nothing- BIKE IS DEAD. Then I spend an hour fiddling and the thing is still dead. Pressing the horn button gives the most feeble wheeze possible and the starter will not even click( just like a dead battery, but the car one is good, starts a diesel benz anyway) Shorting the starter relay gets the starter working and it is good, but the bike wont start. Check more and I have no spark. So I retrace my steps, check everything as I have not done a drastic rewire just cleaned it all up. I find that I have switched the junction box and ignitor box plugs-shit. Have a burnt the effing thing out now? So I reconnect the correct way and there is still nothing. So I wheel the whole bag of bits back into the garage and close the door.

So tell me the worst, have i blown the ignitor? If so are they expensive and does anyone have any ideas on my next steps?

Oh and I have a coolant leak to top it all off. Where the bottom metal pipe bolts into the cylinder, it is small and only a single drop a minute but still a leak. It may sort itself out once things warm up and are running(IF it ever runs.

Thanks, Russ
____________________
I love classic merc's but bikes take up less space.
Current ride is a Yamaha YB 100 and I love it! Oooow and now a running GPZ400R!
Next stop, Direct Access hopefully by the end of summer.

[squishio]

Hey Russ.

No idea what you have or haven't burnt out but I am guessing you have checked all your fuses right?

if you wan't something to test with then let me know as I picked up a full wiring loom off ebay a couple weeks ago (includes everything electrical) so if you need any bits let me know.

Rich
____________________
Current - Hornet 600, Transalp 650, X140 Pit, GPZ400R
Past - SY125, GT250, GT650, CX400, CBF600, Bandit 600, SL1000, GT250

[russeleoin]

Hi Squishio- thanks for the offer. I have checked the fuses and just did a bit more checking. The circut is working up to the Junction Box, what I am not sure about, is that does one of the transistors etc in the junction box have to be energised in order for the starter relay to work? The relay is fine, I have taken that off and tested it and it works, so it must be in the box somewhere. Oh and mine has that burnt electronic component smell( not pleasant) so I guess that something in there is dead. I have my eye on one on Ebay, but if that fails, I will let you know.

Regards
Russ
____________________
I love classic merc's but bikes take up less space.
Current ride is a Yamaha YB 100 and I love it! Oooow and now a running GPZ400R!
Next stop, Direct Access hopefully by the end of summer.

[Gazdaman]

I wouldn't be surprised if your starting problem is something silly like something plugged somewhere wrong. Or a poor ground on the frame.

Or the kill switch is flicked, or clutch switch/side stand switch etc.

Gaz

[alun111]

Have you checked the main fuse/starter relay fuse. It's sometimes located on the starter relay on some bikes.
____________________
Summer: '00 Honda CB600F Hornet
Winter: '93 Suzuki GSF 400 Bandit VP Variable Valve
Past Bikes: Lifan LF100-5 Lifan LF125-A Honda C70

[russeleoin]

Hi Gazda and Alun, ja I have checked the switches, plugging my multimeter in, I can trace the circut from the keyswitch through the kill switch and start button down to the Junction box. All okay there, and the relay does work so I think it is in the junction box. I have the wiring diagram as well. What I dont understand is that the horn is so feeble as well. It is almost as if there is a short circut somewhere????? if it was just the horn or the starter I would think a single failure, but all the electrics seem iffy and they did all work when I started( that old adage of "if it aint broke, dont fix it" springs to mind) I was carful with the wiring and soldered all the joins so it should really be better than before. I will go and have a poke around after work this evening.

Regards
Russ
____________________
I love classic merc's but bikes take up less space.
Current ride is a Yamaha YB 100 and I love it! Oooow and now a running GPZ400R!
Next stop, Direct Access hopefully by the end of summer.

[alun111]

Could just be that the horn is a bit sticky. Take the horn off and try on a good battery (just temporarily attach some wires). If it's still shit, you know it's the horn that's at fault.
____________________
Summer: '00 Honda CB600F Hornet
Winter: '93 Suzuki GSF 400 Bandit VP Variable Valve
Past Bikes: Lifan LF100-5 Lifan LF125-A Honda C70

[squishio]

my horn was also pathetic sounded almost fake as if playing the sound of a horn through speakers but really really quietly.
if that makes sense

replace it with a stebel !!!!

https://cgi.ebay.co.uk/STEBEL-Nautilus-Air-Horn-COMPACT-CHEAPEST-New-Design_W0QQitemZ130310056640QQcmdZViewItemQQptZUK_CarsParts_Vehicles_CarParts_SM?hash=item1e5715aac0&_trksid=p3286.c0.m14&_trkparms=65%3A12%7C66%3A2%7C39%3A1%7C72%3A1683%7C240%3A1318%7C301%3A1%7C293%3A1%7C294%3A50
____________________
Current - Hornet 600, Transalp 650, X140 Pit, GPZ400R
Past - SY125, GT250, GT650, CX400, CBF600, Bandit 600, SL1000, GT250