Project GSXR 400 GK73A -- *PHOTO HEAVY*

[Nope.]

Hi guys,
The other week I went and picked up my new GSXR 400 from a guy in Banbury (Some of you will have seen my thread about Moving a bike in a van). All went well and we got the bike back here safe and sound. It is running and riding (With all but a slight tapping noise from the top end) and the farings look great having recently been resprayed. Now, for the price I paid for it I wasn't expecting a Minter, perhaps something a bit better then this, but its done now.

This is what I ended up with:

https://atechplace.co.uk/BikePhotos2/1.jpg

https://atechplace.co.uk/BikePhotos2/2.jpg

https://atechplace.co.uk/BikePhotos2/3.jpg


Its a nice looking bike but when you look closely you start to see that perhaps it hasn't been taken care of as much as it should have been. The subframe is VERY dirty and theres surface rust in places, the same as with the front fairing frame. So I decided a full strip down and clean was in order. In this thread ill document the restoration process, feel free to chime in with ideas and comments as we go along


So we may as well start with what I spent yesterday and today doing.


First I stripped the front of the bike:

https://atechplace.co.uk/BikePhotos2/4.jpg

I then tagged up the loom:

https://atechplace.co.uk/BikePhotos2/7.jpg

Unfortunately, the front frame had quite a bit of rust on it, bring out the rust remover

https://atechplace.co.uk/BikePhotos2/8.jpg

It worked pretty well, taking off most of the rust.

https://atechplace.co.uk/BikePhotos2/9.jpg


While that was drying I started stripping the rear frame:

https://atechplace.co.uk/BikePhotos2/10.jpg

https://atechplace.co.uk/BikePhotos2/11.jpg


Heres the rear subframe during degreasing:

https://atechplace.co.uk/BikePhotos2/12.jpg

https://atechplace.co.uk/BikePhotos2/13.jpg


And these give you an idea of just how dirty and rusty everything is. I snapped 5 or 6 of these bolts taking everything off!

https://atechplace.co.uk/BikePhotos2/14.jpg

https://atechplace.co.uk/BikePhotos2/15.jpg


More tomorrow
____________________
Former: Derbi GP1 50, Sachs XTC 125, Suzuki GSXR 400 GK73A, Kawasaki ZX7R, Suzuki DR250, Yamaha RD350
Current: 2011 Yamaha XT660Z Ténéré, 2003 Yamaha YZR-R1 5PW (In Build), 2009 Kawasaki ZZR1400

[CaNsA]

Well done with the work

Suggestion:- Please rotate the photos before you upload them.

[Nope.]

[CaNsA]

Defo gonna be keeping an eye on this thread.

Little tip.
use a little wd40 on the rusted bolts and tighten them up a little before undoing them. It will "crack" the corrosion / thread lock.

[Shreddie]

[Redoko]

Nice bike.
____________________
"Let's face it, this is not the worst thing you've caught me doing."
Sudika Sportsman SK50QT > Gilera DNA50 > Honda CBR125 RW7 > Kawasaki Zephyr750 > Suzuki GSXR600 > Honda Hornet CB600F '51

[P.]

[Nope.]

Thanks guys , Yes ive been using WD40 on the nuts but some of them are badly corroded so they just snap when you try to undo them.

I got some more work done today.

First I drained the tank and took it off to find a nice surprise waiting for me:

https://atechplace.co.uk/BikePhotos2/20.jpg

It appears the wire from the thermostat has snapped. I think a new thermostat is in order!

Heres some pictures of what resides under the tank:

https://atechplace.co.uk/BikePhotos2/17.jpg
https://atechplace.co.uk/BikePhotos2/18.jpg


I also took the left side fairing off:

https://atechplace.co.uk/BikePhotos2/19.jpg


Next step, strip out the electrics and airbox and give it all a good clean!

https://atechplace.co.uk/BikePhotos2/21.jpg

P.S. Anybody know a good powder coating company near leighton buzzard?
____________________
Former: Derbi GP1 50, Sachs XTC 125, Suzuki GSXR 400 GK73A, Kawasaki ZX7R, Suzuki DR250, Yamaha RD350
Current: 2011 Yamaha XT660Z Ténéré, 2003 Yamaha YZR-R1 5PW (In Build), 2009 Kawasaki ZZR1400

[mad4it028]

[evoboy]

[Nope.]

[CaNsA]

Good progress

Get yourself a paddock stand!
It will make life a whole lot easier.

[Frost]

So you scraped back all the filth to find an RGV with a 4 stroke engine in it?

[Blau Zedong]

[Nope.]

Haven't really been moving with the project the past couple of weeks due to the car build taking priority.

Got it back into the garage this week and continued stripping it. The batter cage, cdi, most of the loom and the airbox are now off. Im sending off the sub frames for shot blasting and powder coating this week.

Ive also spent a fair amount of evenings the past couple weeks polishing the frame, as im sure you'll see in the pictures below.

(The sainsburys bag is covering the carbs from dust and other crap)

https://atechplace.co.uk/BikePhotos2/22.JPG
https://atechplace.co.uk/BikePhotos2/23.JPG
https://atechplace.co.uk/BikePhotos2/24.JPG
https://atechplace.co.uk/BikePhotos2/25.JPG
https://atechplace.co.uk/BikePhotos2/26.JPG
https://atechplace.co.uk/BikePhotos2/27.JPG
https://atechplace.co.uk/BikePhotos2/28.JPG
https://atechplace.co.uk/BikePhotos2/29.JPG
https://atechplace.co.uk/BikePhotos2/30.JPG

Sorry about the bad photos. Ill get some better ones next time.

Oh, and ive ordered some new parts. The rear mud guard was missing so ive got a new one, Ive ordered a Micron can for it off ebay and Im looking for a new shock.
____________________
Former: Derbi GP1 50, Sachs XTC 125, Suzuki GSXR 400 GK73A, Kawasaki ZX7R, Suzuki DR250, Yamaha RD350
Current: 2011 Yamaha XT660Z Ténéré, 2003 Yamaha YZR-R1 5PW (In Build), 2009 Kawasaki ZZR1400