Project 'cant afford a 7/11'

[virus]

So some of you probably know of my gsx600f rat, some have met it, some have been pillion (sorry mac)

https://i251.photobucket.com/albums/gg307/virusjohn/GSX%20rat/ratty.jpg

Well I decided i was bored of the power and was offered something for a good price, so begun the 'ratfighter' project.

https://i251.photobucket.com/albums/gg307/virusjohn/GSX%20rat/WP_000169-1.jpg

Yep, thats a bandit 1200 engine, I cant afford to do a gsxr7/11, so im doing a gsx6/12

Its been a while of saving up and hoarding parts but the tax ran out on the 6 last weekend and I decided not to re tax it, this means im walking til I get the 12 in, so thats more than enough encouragement to do the job.


So out with the 600

https://i251.photobucket.com/albums/gg307/virusjohn/GSX%20rat/empty.jpg


Swapped rocker covers over for clearance as the 12 is half an inch taller anyway.

https://i251.photobucket.com/albums/gg307/virusjohn/GSX%20rat/rockers.jpg
Bandit rocker cover breather box on the left, 600 on the right, every little helps.


I then found that even that wasnt enough to get clearance for the top rear engine mount bolt to go in. So i Had to chamfer the leading edge of the breather box and remove a face off 2 of the bolts.

https://i251.photobucket.com/albums/gg307/virusjohn/GSX%20rat/skimmedbolts.jpg

As you can just about see in this picture, there isnt much space.
https://i251.photobucket.com/albums/gg307/virusjohn/GSX%20rat/cover.jpg

Infact, the entire bloody thing is tighter than an nuns cunt, I had to oval part of the fuel tank support bar to clear it at the other end of the breather box to get it to clear.
https://i251.photobucket.com/albums/gg307/virusjohn/GSX%20rat/tight.jpg
Note the inner tube inbetween to attempt at removing some vibes.


So now my to do list consists of:
fit exhaust system and make a suitable end can fit
fit carbs and pod filters (cheers temelucus)
fit new rear sprocket and chain
Fit front sprocket cover and bleed hydraulic clutch
Mount a boss for the gearlever to pivot on
fit oil cooler

Then I can fill it with oil and petrol and fire it up.

Ive got a set of gsxr400 gk76a USD forks in my shed and some triumph speed 4 calipers to give the front end some better brakes eventually but for now im going to get the engine in as the frame was, then change the running gear once Ive got the fueling set up.

If anyone knows spring rates and sizes for the gk76a forks that'd be mega helpful as im going to have to beef them up a bit to take the extra 50/60kg weight this has over the gsxr400.



Cheers
John
____________________
own: 81 xs1100g...
owned: 85 rat CG (sold), 91 GS500e (stolen), 84 gsx400f (scrapped), 81 z250 (siezed, siezed, scrapped), 83 cb250rs (sold), 84 gpz750r ratfighter (killed) 84gpz400 (sold), '80 cb650 ratfighter (wrote off) 95gsx6/12f ratfighter (killed) 91 xj900 (sold)
stinkwheel Well I just had my hands up a pigs fanny. Which makes your concerns pale into insignificance.

[P.]

Dear God.

This thing is a monster, please make more.

Ta



This is going to be dangerous, I like it

[Kris]

[c_dug]

Watching
____________________
I am a bellend, I am a man of constant sorrow, I am a gummy bear, I am a rock.

[mysterious_rider]

Funny that, you got offered the engine at a good price? I thought the whole idea of 'ratbike' was to make stuff out of salvage, not buy it, or at least that's what you told me?


Still, looks interesting....
____________________
KAWASAKIIIII

[Trasler]

Holy shit that bike is gorgeous. I would love a bike that was perfectly fine, like pristine condition, but then looked like it was a wreck. Like what they did to this car;

https://www.youtube.com/watch?v=68rboqKs8Ys
____________________
Current Bike: 2005 Suzuki EN125-2A Grey.
Dream Bikes: Harley Davidson Roadster 883, Triumph Bonneville (British Racing Green) and Norton Commando 961.

[virus]

m_r, the thirst for horsepower is never ending, and this is cheaper than buying a bandit 12, still ratting I just need more of a hooligan device
____________________
own: 81 xs1100g...
owned: 85 rat CG (sold), 91 GS500e (stolen), 84 gsx400f (scrapped), 81 z250 (siezed, siezed, scrapped), 83 cb250rs (sold), 84 gpz750r ratfighter (killed) 84gpz400 (sold), '80 cb650 ratfighter (wrote off) 95gsx6/12f ratfighter (killed) 91 xj900 (sold)
stinkwheel Well I just had my hands up a pigs fanny. Which makes your concerns pale into insignificance.

[mysterious_rider]

[evoboy]

I am SOO glad this has finally begun.
____________________
Suzuki GT250 x7------- Fazer 600------CB250RS------Aprilia Rally 70----- Bandit 600

APT Motorcycles

[UnspeedySam]

Watching. Looks epic
____________________
Riding: BMW R1150RT `02 bought mildly crashed
Fixing: Also the BMW as I get less broken bits
Gone: ZZR600 '00, TRX850 '97, RXS100 '93, JS125-6B '07, BMW R1100RS '93, Kawasaki ZX-6R-J2 '01, Honda Bros NT400 NC25 '88

[Tim..]

Hope you did the valve clearances before bolting it up, good luck doing it now.
____________________
Project builds: My VFR400 nc30 build thread + Honda Britain Rep VFR + What? Another VFR +Project 'cos I want one' + V8 coffee table
www.marshallracing.co.uk
OCD - Helping to bring the standard of my bikes up and make me slowly go mad since 1999

[virus]

m_r, bit far south for me for a day trip but you never know, I may well turn up.

Tim, valve clearances were done on the bench, well , the 3 that needed adjusting were, sel on the more open end of the scale so they wont need adjusting too soon as it is an engine drop job to do it. Its ok though, bandit 12s go for ages without needing valve clearances done.


Cheers
John
____________________
own: 81 xs1100g...
owned: 85 rat CG (sold), 91 GS500e (stolen), 84 gsx400f (scrapped), 81 z250 (siezed, siezed, scrapped), 83 cb250rs (sold), 84 gpz750r ratfighter (killed) 84gpz400 (sold), '80 cb650 ratfighter (wrote off) 95gsx6/12f ratfighter (killed) 91 xj900 (sold)
stinkwheel Well I just had my hands up a pigs fanny. Which makes your concerns pale into insignificance.

[virus]

More progress today, first of all I dealt with the front sprocket cover.

The 600f cover has a boss for the gear change lever yet the bandit 12 one doesnt. Luckily it is removable.

https://i251.photobucket.com/albums/gg307/virusjohn/GSX%20rat/sprocketcovers.jpg

So a bit of hammering got that out, and then I drilled a hole in the bandit front sprocket cover to mount it, however the rose joint at the lever end was colliding with the raised part of the cover.....

So I chopped up an old imperial ring spanner as a spacer, job done.

https://i251.photobucket.com/albums/gg307/virusjohn/GSX%20rat/spannerspacer.jpg

the more observant will notice the chain is slack


Next was the exhaust, after mounting the downpipes I noticed the main stand eyelet on the frame was in the way.

https://i251.photobucket.com/albums/gg307/virusjohn/GSX%20rat/exhaustfail.jpg

Luckily, I don't have a main stand, and neither do I give a shite about that bracket, so out came the angle grinder, and on went the kerker.

https://i251.photobucket.com/albums/gg307/virusjohn/GSX%20rat/pipewin.jpg


Next was to fit the air filters (cheers temelucus)

I decided to use the airbox snorkels from the gsx600f airbox, primarily because the pods kept popping off their mounting rubbers thanks to the bandit carbs having oval inlets. However by doing it like this it reduces turbulence in the air intake, which is the biggest nightmare about tuning CV carbs on pods. hopefully this will help me later on when Ive got to get it running well.

https://i251.photobucket.com/albums/gg307/virusjohn/GSX%20rat/pods.jpg

It was at about this stage I got eager and decided to throw the bodywork back on it to see how it looks now.

https://i251.photobucket.com/albums/gg307/virusjohn/GSX%20rat/mockup.jpg

not too dis similar from how it was before but still, nice to see it in one piece (ish) again.


I then decided I needed to make a shield for the pod filters to prevent rain ingress, this was made out of an old 'permit parking only' sign I had lying around, roughly bent to shape and thrown on.

https://i251.photobucket.com/albums/gg307/virusjohn/GSX%20rat/podcover.jpg

Ive still got to finish shaping it to suit and drilling mounting holes for it, but im quite happy with it so far.



So still left to do:
change spark plugs
fit oil cooler (waiting on new lines)
fill with oil
get baffle pack material and repack exhaust
Replace throttle cable as the current is too short
finish filter shield
remove 2 links from the chain then join it up
bleed/replace clutch master cyl, I cant for the life of me get it to bleed and i suspect It might not be giving out pressure, although It was empty when I fitted it so no doubt it'll take a while to bleed the system.



Cheers
John
____________________
own: 81 xs1100g...
owned: 85 rat CG (sold), 91 GS500e (stolen), 84 gsx400f (scrapped), 81 z250 (siezed, siezed, scrapped), 83 cb250rs (sold), 84 gpz750r ratfighter (killed) 84gpz400 (sold), '80 cb650 ratfighter (wrote off) 95gsx6/12f ratfighter (killed) 91 xj900 (sold)
stinkwheel Well I just had my hands up a pigs fanny. Which makes your concerns pale into insignificance.

[Slacker24seve...]

Gis a go mister!!!
____________________
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

[jtheodore27]

i've seen that bike about, pretty sure you live around the corner from me

[Blackwolf]

Virus, that's cool to see a new engine! Was funny seeing Robbie ride the Keg!!
____________________
Current: Ducati Multistrada 1200s

[Zen Dog]

Nice, the teapot flies again! Looking forward to seeing the finished product at the next BBQ...

Zen Dog
____________________
Current - '94 VFR750FR (Dead), '00 VFR800FI, 2011 CBF125 Previous - '10 Street Triple R, '92 MZ ETZ301, '05 TTR250, NSR125R, KMX125, "Honda" Win (chinese copy of an old Honda design with a C90 engine)
My bike trip around S.E. Asia 2010/2011

[virus]

b-watson, are you in worcester? i wouldnt be surprised if you've seen it before, its somewhat recognizable and always around worcester. What do you ride?


zen, hopefully should be done by then, not much left to do apart from carb tuning after the last few days. Update soon


Cheers
John
____________________
own: 81 xs1100g...
owned: 85 rat CG (sold), 91 GS500e (stolen), 84 gsx400f (scrapped), 81 z250 (siezed, siezed, scrapped), 83 cb250rs (sold), 84 gpz750r ratfighter (killed) 84gpz400 (sold), '80 cb650 ratfighter (wrote off) 95gsx6/12f ratfighter (killed) 91 xj900 (sold)
stinkwheel Well I just had my hands up a pigs fanny. Which makes your concerns pale into insignificance.

[jtheodore27]

[virus]

ah you must be just around the corner then
____________________
own: 81 xs1100g...
owned: 85 rat CG (sold), 91 GS500e (stolen), 84 gsx400f (scrapped), 81 z250 (siezed, siezed, scrapped), 83 cb250rs (sold), 84 gpz750r ratfighter (killed) 84gpz400 (sold), '80 cb650 ratfighter (wrote off) 95gsx6/12f ratfighter (killed) 91 xj900 (sold)
stinkwheel Well I just had my hands up a pigs fanny. Which makes your concerns pale into insignificance.

[mysterious_rider]

Out of interest fella what are you doing with the standard engine? Is it just a bandit 600 lump? I have a feeling mine might have a half serious top end problem ( )
____________________
KAWASAKIIIII

[UnspeedySam]

[mysterious_rider]

[virus]

So over the weekend I managed to get some more stuff done.

New oil lines from redline hydraulics made up and fitted (350 bar rated hose, 25 ish quid for the pair, fuck yourself suzuki im not paying 50 quid per side for NOS)

filled up with oil, changed spark plugs.

Bled the hydraulic clutch.

Joined the chain up.

Got it running, Ive got a video but youtube is being a bastard about it. It runs like a bag of shite anyway because Ive still got lots of carb tuning work to do, but it runs, so im happy.


m_r, the 600f engine is a slightly higher state of tune than the b6 iirc, its going on ebay when i can be arsed to put it up, it needs 2 studs removing from the exhaust an oil cooler fitting and a new front left cover but apart from that its in one piece, id like 200 notes for it.

Cheers
John
____________________
own: 81 xs1100g...
owned: 85 rat CG (sold), 91 GS500e (stolen), 84 gsx400f (scrapped), 81 z250 (siezed, siezed, scrapped), 83 cb250rs (sold), 84 gpz750r ratfighter (killed) 84gpz400 (sold), '80 cb650 ratfighter (wrote off) 95gsx6/12f ratfighter (killed) 91 xj900 (sold)
stinkwheel Well I just had my hands up a pigs fanny. Which makes your concerns pale into insignificance.

[Slacker24seve...]