Suzuki Bandit 1200 — The Old School Hooligan Tool.

Bigger cubes!
Part of the reason for putting the GS550 on the road was to take things at a gentler pace. While the CBR600RR is amazing — compliant, smooth, light, quick — probably too quick, you need to be a bit careful where the constabulary are concerned.

Ambling round on the GS is great, it's happy mooching round and gives you plenty of time to take in the scenery. I absolutely love being on old stuff too. Points and condensers, carburettors, air-cooled engines... they just have more soul. The smell in the garage after they've been for a run is awesome too.

But then you hit that steep hill, loaded with hairpin bends, and she struggles in first gear just to make it round. It starts me thinking about GS1000's, GSX1100's, something a bit bigger, torquier. Something that will go two-up with ease, trundle around all day on the sniff of fumes and sit at 3,000 to 4,000 RPM.

Mmm... nice but too expensive nowadays. 

So, it got me thinking. What about the first of the Bandits? 1157cc, oil/air-cooled monstrous fours that ooze torque and charisma, and will wrench your arms off just off idle. Basically the detuned engine out of a GSXR1100. Always wanted a GSXR1100. Mmm, here we go again!

Gumtree.
Such a visual feast of all things bargain, if you look properly. There were lots on there, later 1250S models with the water-cooled engine, but all were runners and commanding large sums of money. I prefer a project for much smaller sums of money. And I found one. But it was a thirteen hour drive, for a non-running Mk1. It looked in reasonable fettle (obviously in photos) and Murray, the guy selling it, seemed pretty legit, in fact an absolute legend. So transport was organised...

Suzuki GS550E — Replacing The Clutch.

EBC Heavy Duty Springs.
So after a few rides on the old 550, it soon became apparent there was a bit of clutch slip when used hard in high gears, but the main issue (for me) was the clutch lever was just too light. To the point that when you were trying to get away from the lights, especially uphill, the clutch just wouldn't bite fast enough.

So Wemoto quickly sent me some new springs, and a Slinky clutch cable in case the old one couldn't take the pressure. These guys are amazing, great prices, very quick and efficient service!

Back On The Road — Suzuki GS550E

From a parts bike, to potential mileage muncher.
It was a little cheapie, bought unseen on eBay. My famed acquaintance Bryan picked it up for me, and even delivered it to the door... I swear legends are made of less. Pretty sure he's dying to ride it too.

It wasn't pretty, but he's a mate. The GS was also rough, no plugs in the engine, the carbs in a box and broken, but with seven years of TLC, dedication and, pure laziness, it's back on the road.

Considering the massive oil leak when the engine was first turned over, the fact that the bores were left exposed for however long, and the carbs had been left off too, it's incredible how good this thing goes and sounds. 

I put a cam chain on it, adjusted valve clearances, new coils, plugs, points and condensers and it runs like a bought one.

With a first test run (shakedown) a few nights ago, I discovered I need to fix a few things:

1) The gear lever circlip fell off and the lever nearly went astray. Luckily the foot peg bracket just held it in place.
2) The clutch slips slightly under load, heavy-duty springs are on the way. 
The lever itself feels so light, it's hard to pull away from standstill — definitely needs more pressure.
3) The seat is too low, and too firm, but the cover itself is still pliable and soft. I assumed somebody had cut away the original foam for a shorter rider, but maybe it's sunk over the years. I've ordered a section of gel to go into the seat for a little more height and comfort.

In fairness, it goes very well. I'll get some of these little jobs done and keep you all posted. Never done a gel seat conversion so looking forward to that. This is how it looks now — not immaculate, but definitely useable.

I'll clean up and paint the exhaust as and when, but for now need to get some miles on it. Hopefully the gel will arrive this week so I can sort that out.

More soon...

GS550E Paint — And Now The Lacquer.

2000 Grit Wet & Dry
After a good flatting with soapy water and the old P2000 grit, the paintwork was looking smooth and, well, dull. Taking care on the curves and edges not to rub through the red, you're aiming for paint that is uniform all over without any orange peel. 
The scary part is taking your nice shiny paint finish and ruining it. 
But if it worries you, just run water over the paint and watch how it shines again — that's what the lacquer will do.

Fast From The Past — Awesome Place!

While perusing the internet the other day for a Paulo Tarozzi fork brace I, quite luckily, happened across this place — Fast From The Past. 

And I found they are an absolute goldmine for old race bikes, cafe racers etc. because they carry those quality parts that are hard to find. Often you find a shop that only carries certain items for a few bikes, and my GSX often comes up lacking.
But here, a fork brace for the GSX750ES is just one of hundreds of different types available, all at realistic prices. And, once ordered, it was delivered to me in Australia in around a week. Nicely done.

How retro is that box? Love it!

I'm Seeing Red... Monza Red.

Amateur paint jobs.
Because I just wanted the GS550 to look good enough to go back on the road without any fineries and, because I'm too tight to pay the extortionate prices needed to get someone to spray it professionally, I'm doing it with aerosols. 

GS550 - Fitting New Points and Condensers.

Fitting what?
Contact breakers, remember them? It appears that many of the younger mechanics coming through don't really know what points and condensers are. Maybe they don't teach them the basics of ignition systems in college anymore, maybe they take no notice because they've never had to fit any.  Probably the latter.

Maybe I'll start with how they work.

To get a spark to fire across the spark plug's air gap, we need a pretty high voltage (20,000 - 30,000 volts), for which we use a coil. Everyone's familiar with those, but just how do you get a spark out of one?  Without electronic jiggery-pokery CDI and transistorised ignition systems?

Suzuki GS Engines — Checking Valve Clearances.

Basics — why do we need clearance?
In an ideal world, the combustion chamber in an engine would be completely airtight during the compression stroke. However, due to basic mechanical inefficiencies, there will always be blow-by somewhere. But by keeping this to a minimum, your engine is able to produce good power. 
Possible ways for the air/fuel mix to escape could be via the piston and rings, through a failed head gasket or the valves in the cylinder head. Because we're dealing with valve clearances today, we'll stick with those. 
In modern engines, the poppet valves in a four-stroke engine are either machined perfectly to form a seal against the 'seats' in the head, or lapped in with grinding paste to match them together (older engines). Springs then hold them tight against the seat and, voila, no air leaks. 

Suzuki GS550E. In this pic you can see the two camshaft lobes above their respective bucket and shim. The cam cap is removed because some clown (previous owner) stripped a thread — in fact they mullered a few of them and decided to replace them with some coarse-threaded bolts! Marvellous.

Omnia Racing Headlamps... Cool Quality.

A BIG thumbs up!
I saw a CBR600 street fighter doing the rounds on one of the forums lately and, to be fair, it was a nice build. What really stood out for me was the headlamp — not in the "cheap, Chinese, badly-finished rubbish" type of way, but more "Buy Me Now! I am the quality you look for" — so I asked the owner of the bike where I could get one. 

As he looked at me, I could see his face contorted with pained expression. He gave a quick glance over his shoulders to check for eavesdroppers nearby, and he slowly whispered the words Omnia Racing... I looked behind me, was about to ask more, but he was gone.

So I started looking online. Based in Italy, with an impressive website full of expensive bike exotica, they also had an eBay store and I found just the unit to set off my GSX in a way that would somehow complement the odd-shaped ESD tank, along with my crudely knocked together tailpiece. Sort of.

Frayed Clutch Cables, And Making New Ones.

When you alter anything from standard...
Inevitably something must change with it. The clutch cable was way too long since I've dropped the handlebars down, and although I'd managed to 'lose' some of its length, it wasn't quite right. 

But it worked; until it frayed. So I bought a kit to make a custom one myself. 

Having seen the job done by Gordon at Lucas Motorcycles, Ross-on-Wye loads of times over the years, I figured I knew all the tricks of the trade. Whenever I had a cable issue on my bikes as a kid, I'd be straight up the dual-carriageway to Ross and he'd make one for about ten quid. Bargain, and that was at any time up until 9.00pm everyday of the week... the guy was a legend!

So if you have an issue with cable length, an odd bike or the original part is too expensive, take a look on eBay and check out the kits available. This one came from the UK and is a quality bit of kit, nylon lined for smoother action, oo'er missus.

DANGER! Scared Of Using Engine Flush?

Skeptical, or concerned?

You will find different opinions on using engine flush from every mechanic out there. Some say never use it no matter what. Others put it in at every oil change.

So why the difference in opinion? What are the pros and cons?

Valvoline detergent-based engine flush.

Bloody Exhausted! (I'm so funny...Suzuki GSX Humour).

Link Pipes Done.
With the merge collector done, I needed to make the links to the reverse cone mega's. I decided to cut up loads of little sections of stainless pipe to get the correct angles for the link pipes. I could have done it with fewer, longer sections but decided the "loads of welds look" was the way forward. Maybe, when you know how to get the pretty colouring of welds to work for you, but it looks like a jumbled mess now. 

Still, it's on and the bike sounds bloody great! And it was a good experience too, giving me plenty of ideas for the next go, and that's how we learn. I've been wondering how the bike would sound for ages, and I'm not disappointed. You can hear it in a video at the end...

Petrol Tanks, Filling Dents, Priming... Meh!

Unskilled.
Not my favourite job if I'm honest. I spent ten months prepping cars for paintwork a long time ago, but I think the very little I actually learnt has slipped away to oblivion. The guys I worked with made it look so easy. 

I'd spend hours applying filler, rubbing it back, going too low and having to start again. They seemed to be able to perfect it in minutes. But, alas, the tank I wanted to keep in bare metal has just too many dents and marks for me to be happy with it. So, I decided to break out the filler. 

First job was to get the bottom ready for primer. Once painted I can refit the fuel gauge sender and tap, and double check for leaks before spending hours on the top.

Flatted with 360 grit paper, it was soon good enough for some filler primer. 

Greasing The Suzuki Speedo Drive.

Funnily enough... grease dries out and goes hard after thirty years of getting mashed in a worm drive, but how do you get the speedo drive apart without ruining the seal? Once they're put together, it's nigh on impossible to remove it — and you can't buy the drive complete now, let alone get the right seal! 

So, after a lot of messing around with a spare one I have, I decided to have a stab at getting it apart with minimal damage. I came to the conclusion that a 2.5mm hole drilled through the body of the drive itself would allow access for a small punch to tap out the seal. If all goes to plan, a small dab of silicone in the hole will seal it up once finished. Job jobbed.

Symptoms.
Just turning the tabbed washer will tell you how bad it is. If it stops, gets stuck and generally feels tight, it needs to be stripped, cleaned and greased. Leave it and the tabbed washer will fail, maybe even the worm drive and gear itself. The drive in my ESD has had the tabs brazed back on at some stage. And this spare drive has quite a bit of wear on the inner tabs where it fits into the gear.

Whatever happens, it would be good to take a look inside and see what can be fixed. With a centre pop first, and then very slowly with the drill I had enough room for a small punch to tap on the back of the seal.

The Suzuki GSX750ESD Continues — At Last.

As projects go... this one is dragging. 
I've been doing too much other, altogether mundane, stuff rather than concentrating on the cafe. But I have a couple of weeks off now where I should be able to make an impact. I also had some business cards made recently, purely to advertise the blog, but I want to get busier on the bike before I start passing them round. The backs of them are useful as a service log too, so keep them in your wallet and you'll know when the old beaut needs another oil change.

Biketech7 and Champions Ride Days - QR 24/10/2015

Never a bad day!
Last time I was at Queensland Raceway I came off at turn four, but even that day turned out pretty good in the end. That was over a year ago. Today there were three of us heading up, plus Will on photography duties, and we were all in blue. We were there at 7.00am so had plenty of time to sign on, get the bikes sorted and kit up. Briefing was quick, and soon enough yellow group were out on a fast one.

There was some nice stuff up here today, and not many bikes make a 1290 Superduke look boring, but in our very own group of blue there was this Kawasaki H2R. More on this later.

GSX750 Cafe Racer Progress - Battery Box.

Back in the garage.
Finally got some time to crack on with the wiring and battery box. It's been bugging me for a while because I wanted the loom to look perfect, but sometimes you just need to make a start and fix any issues later. 

I'm still unsure on what sort of speedo/tacho combination I'm going to use too. I'd like two separate units to mimic the typical sixties/seventies bikes, but I have a certain budget too. The modern digital versions get very expensive when you go for quality versions. And although there's plenty of Chinese versions on eBay, do they actually work for more than ten minutes? Decisions...

Gasket Paper.

Doing It The Old Fashioned Way.
Because my brand new, fitted two years ago, gasket broke when removing the clutch cover, I needed a new one. No longer available from Suzuki, you can find quite a few New-Old-Stock ones for sale on eBay - for the price of an aftermarket gasket set! Seriously, are they gold impregnated?

Being careful with my funds, I shot down to Repco for a sheet of the old oil resistant stuff. Just under twenty bucks, plus a further 30% discount that weekend for being an RACQ member, and I was the proud owner of a roll of Flexoid gasket paper. 

Made in England!
That's refreshing, should be good then.

Copying the original gasket, and with a little help from Stanley's knife, and Snap-On's hole punch set, I soon had something that resembled the first one. Even the bloody holes lined up!

With all that done, I had to hear it running again. It's been a while, and I want to be able to run a flush through the engine. So loom was laid on the bike and bits connected where they should be. This loom is a mess! I need to have a big clean up and remove the rubbish repairs from previous bodges. 
With battery connected, I checked for spark - all good. I filled the syringe with fuel until the float bowls were all full and gave it a whirl on the starter. The odd firing occurred and then she was away!

It Never Rains...

But it does pour a lot!
The Easter break gave me a chance to not only procrastinate some more, but actually get a bit done on the GSX. I decided to fill the front brake lines with a beautiful blue DOT3 fluid, just so I could check for leaks and feel at the lever. The Chinese reservoir was duly fitted, and ten seconds later developed a leak from the sight glass. Tossers! 
It came off pretty bloody quickly as my freshly painted headlight switch sat underneath it. So a plastic reservoir was put on loosely while I bled them. The anti-dive units haven't held fluid for years so I was expecting problems, but the only issue was a slight leak around the banjo bolts. With a bit more tension applied to the bolts, all seems good. The lever is a bit on the soft side, but should improve once the pads have bedded in. 

Oil be fooked!
Next job was to put a new oil filter in, fill with oil and crank it on the starter to see if the oil light would go out. As previously mentioned, the wire to the oil pressure switch was 'missing' - which could spell trouble. The 'oil light' for today being my test-light mounted between the switch and the live terminal on the battery. It lit up nicely, but refused to go out once cranking. Bugger!
Could the oil pump have gone dry after all the months of sitting around with no oil? Had somebody removed the wire because the engine is fuckered? Was there more to this conspiracy? Oh joy.
I wasn't taking any chances, the sump was taken off to check the pick-up gauze.  The sump itself was full of thick, treacle-like oil and in desperate need of a clean out. Degreaser and brake clean soon had it spotless, but it's a worry that all that  was running round the engine. The oil pick-up was holding a tiny amount of carbon, but not enough to stop the oil pump sucking and pumping the brown stuff around. So, with all that cleaned up and blown out, the sump was refitted with a new gasket.

Playtime with a GSXR750 L2.

Thank F... goodness For Seven-Fifties!
They were all the rage in the '90's. World Superbikes kept them firmly in the minds of any pub road-racer. I was just starting out on the road, but wanted a blue ZXR750 with those Hoover tubes looking so bloody cool coming out of the tank. Ooh yeah. And let's not forget the rare RC30...
Local fast boys had GSXR750's and wheelied from the lights constantly, telling me about the gearbox rebuilds from continual wheelie abuse. It was music to my ears at that age! Yeah, there were 1100's, and the all new Fireblade, but it was the 750's that were racing round the track against 916 Ducatis. 

And then...
Everything changed. 600's got quicker, the R1 came along and annihilated the ageing 'blade. A few years later, Suzuki had a thou too and suddenly WSBK was destined for 1000cc fours as well as the V-twins. The midrange 750's started to die out - after all, they weren't wanted in terms of sales. The ZX7R hung in there for a while, but the only true sports bike to maintain that displacement was the GSXR, all those years after it's formidable launch in '85.

And what a good move by Suzuki. 
Yeah, thou's are great fun 'cause they're quick. But how much power can you actually make use of on the road? There was a time when a big bike was limited by its poor chassis. You might have horsepower, but you're going to die if you try to exploit it. Not so much nowadays. They let you get away with a lot, but also make you very lazy. Someone faster than you in a corner? Just open up on the straight and reel him back in. You end up riding around on quarter throttle thinking you're Troy Bayliss, while there's a 600 stuck up your chuffer trying to hurry you along in the corners!
Looking at the latest thou's now, I can't help thinking that all the electronic aids designed to make them faster/safer are dulling the basic virtues of riding. Launch control, traction control, wheelie control... strewth, what about my control?
Sure, gadgets are great, but go out there and get on a real bike for a bit. Give the brain something to do, you might actually enjoy it...