Bandit project

The idea is to leave 2 bikes in Tasmania and fly down whenever time allows . This saves 2 weeks in travel alone and probably $2000  per trip.
Carol chose anEr5  cost $2000.
I spotted this near home and got it for $800 .
So project Bandit 600 starts .


2 hour later .Carbs on on the bench , impact driver used once .

No water cooling , no anti pollution crap , this is great . I idea is to strip and rebuild .

nice gus! glad to see you have come full circle.

Great score Gus , look forward to seeing the end result ..................and it is already black 

I think you'll miss the power of the 1200, but pretty good pick up regardless

Looks like a fun project

Are you taking suggestions Gus?
Here is mine - longer forks, swing arm, knobby tyres - Worlds first off road Bandit? (with a red frame in Tasmania)

The weight of the 1250 in Tasmania was real pain. Ive had a 1200 so i'm looking forward to lighter and power I can use .

Better hope it rains Gus - more days in the shed! 

I know you'll turn it into something special Gus and the 600 wont be wanting on Tas roads.

After all this rain washing away the roads and bridges you might just need an off-road bike 

Frame completely stripped and motor on the floor takes a total of 5 hrs .
Inspection time .
Heart skips a beat when I notice front sprocket nut just spins on the thread and sprocket wobbles all over the place . I have visions of no thread on the shaft. I remove the tiny holding bolt and the huge sprocket nut falls on the floor with no thread at all . Luckily the thread on the shaft is fine .
Two bolts sheer off in the head when I remove exhaust headers . To be honest I was expecting more .
Check valve clearances ,a bit tight ,so adjust . Screw and locknut , what a great motor to work on .
One cam cover bolt has no thread ,or any thread to screw into .
All the linkage arm bearings (shock ) are stuffed ,must be replaced .
Swingarm bearings or not to bad .
Steering head bearings  poor ,to be replaced a bit later on .
Over all ,just minor stuff to replace or fix . 
Shock looks terrible but cleans up ok . Chrome on shaft look perfect . The oil either has leaked out years ago or is still in the unit . I have a good laugh because I can see someone has painted the spring yellow with a paint brush .Who paints a spring but doesn't replace a knackered sprocket nut .
Wiring loom is perfect ,frame good paint ,even if it is red .I was going to paint the frame black but it can stay red seeing its less work .
Tomorrow its rattle can time . Frame ,swing arm and motor will get a touch up and some bearings in the linkage arm so I can keep going .

could have been a whole lot worse Gus

Try and remove two snapped of bolts from head (not mine ) . drill centre of bolt ,going well . Drill next size , drill bit brakes in hole .F&%#@$k
Turns into a disaster . Get totally pissed off .Lokk fooor Alcahol  ,found it .

gus wrote: drill bit brakes in hole .F&%#@$k

probably the worst thing that can happen getting a piece of bolt out.

It happened to me a couple of times years ago when I was working in a Marine environment, can you get anything in the drill bit flutes? small nails?, IIRC once I used a couple of old GM injector pins then managed to grip them with vice grips and eventually wriggle it out, another time it was a bit larger and I was able to smash the drill bit with a hardened punch

Good Luck, think you might need all of it and a bit more 

Fingers crossed you can get that Bastard out. I think we've all had one of those moments with seized bolts. I am not a fan of small easy outs either as they break just the same

Its in there for life now . Unfortunately it broke off half way in the hole ,so there was now way of grabbing it . I knew it had about 8mm of space in front
of the pointy end of the drill bit till it reached the head . I punched it in the 8mm and managed to put in a 6mm bolt behind it . Then cut the head off the thread .I'll just put a nut on it to hold the flange in place .
Motor is back in and about 70% complete . Now I realise I havnt see a regulator |rect. any where .
I'm guessing there should be one . Anyone Know where it should be 1996 Bandit .

inside the alternator.

Sweet , I need a manual  ,about time you came out for a visit .

I have one

gus wrote:Sweet , I need a manual  ,about time you came out for a visit .

Hello Gus, this manual may be of interest.

If you have any problem with the download, let me know and I'll find another way.
Anyone else who wants early 600 or 1200 info. can click too.

Manual

Password= recycled

Try this site, got a couple of different manuals for download including the factor 1995-99 GSF600:

Bandit Manuals

I don't get on well with computer manuals . I'm old school , a book please .
Clean and degrease every single part .Realise the bike has been resprayed from red to black . Explains the red frame .
Things going well ,got a bit lucky with the bike being totally stock .Tomorrow should have it back together .
Had to order bearings .

gus wrote:.
Clean and degrease every single part .Realise the bike has been resprayed from red to black . Explains the red frame .

Must be destiny Gus ...............someone else with a love of black paint............

gus wrote:


2 hour later .Carbs on on the bench , impact driver used once .

You are my new hero ,Gus. 
You have more bikes than Ewok - and that's just in that photo.

(Yes, Dave. That's a dare)