[Kartoon]

I figured I might as well post my build for my Bandit on the site.

My bandit at the last stage of its life had 75,240 miles on the original engine. It had Holeshot stage 2 jet kit, pods, 5* timing advancer, Holeshot full exhaust, both GSXR cams, naked, GSXR 1100 front forks and rear shock and was painted black with red flake.

The engine grenaded at some point in cylinder three, in which the piston was destroyed and one valve was found in my oil pan.

More tear down pictures:

 

[Kartoon]

Now it was time to collect the parts.

I decided that even though they are longer, I was going to use the Hayabusa rods.

I was not planning on getting new carbs yet but I came across some on ebay and I bought some Mikuni RS40 for it. Some people have said they dont need to be this big and others say if tuned properly they will be fine. I plan on using these for now and see what happens. They do fit the stock manifolds although they sure are tough getting in there.

Next up I got a new head, by our own Gary Dye. It is ported, 30mm intake valves, HD springs, valve job and new seals.

 

[Kartoon]

New air filters:

New cam chain tensioner:

Old crank back:

Cylinders bored, new sleeve in #3:

New 1246 pistons:

And just for fun, a comparison :bash: :bash:

My first shipment of gaskets, orings, etc, plus a brand new cam chain.

I am using a Setrab 19 row oil cooler and making my oil cooler lines. AN8 oil pan adapters:

Because of what my cam guides looked like I decided to buy new ones just in case

 

[Kartoon]

I am also doing the home made cam links. Because the allen head bolts from the Bandits wont work, I bought 4 GSXR bolts and then drilled and tapped them for the banjo bolts. I have everything to make them now, all black 4AN fittings and black nylon braided hose but have not done it yet since I was more concerned with getting the engine running.

I needed new tires so why not. I bought the Pirelli Angel STs.

I didn't pictures at all of the engine assembly as I was too busy actually doing it. All bearings were replaced, alone with the cam chain, guides, etc.

Putting the two cases together was not that tough at all. As I read, most trouble is getting the forks to line up in the proper places when lowering the bottom case onto the top but mine went together rather smoothly.

Before I could throw the motor into the frame I had to re paint some pieces and get a rolling chassis. My frame and swingarm I had already painted black 4 years ago, so I figured while the motor was already out it would be a good time to repaint them.

Also re painted the hugger:

Painted the triples and forks black. Do not have pics of just the forks, but can see in the assembled pics.

I also painted me wheels black to get rid of that ugly Suzuki finish and got the tires mounted by myself without scratching them too.

Now with all that done I could begin to make my rolling chassis:

 

[Kartoon]

With the cases put back together and the bottom of the motor I could throw it back in the frame. The bolts and spacers you see are to get the block seated down so I could measure for my base gaskets.

Rear end of the bike pretty much all set

With my base gasket and cylinder spacer I could get the block and the pistons in and all set

Head...

Cams are in and degreed.

And then the rest of all the motor parts went on

I had to do some body modifications so I took the first gen tail, shaved off the grab rail holes and then fiberglassed all three pieces together to form one tail section.

Had to do some body work to my GSXR fender

And then I decided I did not want another black bike. Everyone paints their bikes black and it doesnt stick out. So I did mine in a pearl white tri coat.

AND THEN IT WAS FINISHED(for now)

 

[Kartoon]

Here are some better pictures of the bike with some sun out. Enjoy.

Shaved tail section

Pearl white does not photograph too well.

Aprilia Brembo masters:

Setrab oil cooler

Mikuni RS40s, APE air filters, Pingel fuel valve

New Pirellis

Painted forks and triples

 

[Kartoon]

Specs are as follows:

1997 Suzuki Bandit 1200
JE 1246cc pistons (#128885) 13.1 comp ratio. .045" milled off pistons
Hayabusa connecting rods
Gary Dye ported head, 30mm intakes, HD springs
Mikuni RS38 Flatslide carbs.
Holeshot full exhaust
1989 GSXR 750 Camshafts, intake and exhaust, degreed 104/106
Setrab 19 row oil cooler, black nylon braided lines
APE manual cam chain tensioner
APE Air filters
Stock base gasket
Cometic .080" aluminum cylinder spacer
Cometic MLS head gasket

Non motor related parts:
GSXR 1100 front forks
GSXR 1100 rear shock
2008 Aprilia RSV 1000R Brembo radial masters
Venhill smoked stainless front brake lines
Corbin gunfight seat
Renthal Streetfighter bars
Pirelli Angel St tires
ZX9r 6 piston front calipers

 

[Kimmo57]

Nice!

 

[Kristjan]

Your blown motor reminds me my FZR1000 EXUP, which I sold for parts a while ago. It snapped a exhaust valve, bent the other one next to it, completely ruined the combustion chamber, broke a piston, cylinder liner and bent the rod and also spinned 3 rod bearings. All that while doing 10000 revolutions per minute.

Good project, worth keeping an eye on this.

 

[94yzf75fighter]

Nice build

 

[DrJellyFingers]

Well done. Love the finished product

Sent from my LG-P769 using Motorcycle.com Free App

 

[Kartoon]

Thanks guys, I have since changed the headlight to a single bi-xenon projector. I know its not a total fighter, but its my commuting bike and I use it for 2-up riding so I cant get rid of the comfy corbin seat. If I ever get a different bike for commuting so then I will probably chop it up some. This bike has been in my family since day one so I would love to keep it for a long time.

Heres a not so good picture:

 

[RICH S202]

Fook me, looks like mine

BTW you need to run another feed from the valve cover into those cam links to create a proper top-end oiler system, otherwise they do fap all.

Tasty looking bike though mate.

 

[Kartoon]

You cant beat black and white!

I did have a hose running to the valve cover, just no pictures of it. I used the setup last summer but at the dragstrip the bolts kept loosening up and weeping oil, so I just ditched the whole idea for now. I need longer bolts of the side of the head but its hard to find something long enough that is a double banjo.

 

[a_morti]

You can't just threadlock them in place?

Great work, real attention to detail. I like how much you can change in suzi engines, even if I don't want to own one myself. It's enough to make a real geek out of anyone, perfect.

 

[Kimmo57]

Thanks guys, I have since changed the headlight to a single bi-xenon projector.

Where'd you get it?

 

[Kartoon]

Where'd you get it?

It is from an Infinity G37 headlight. Used the projector and the ballast.

 

[F'dup]

Very clean work!
Shaved tail turned out great, subtle change but very well worth it...

 

[backinblack69]

OOOOOOO SO nice I am jealous but great bike mate and with that type of power on a bandit I can just think that it goes like a bullet well done great enjin job...

 

[gsf1200R]

So I have a Motor Related Question.

Did you Pull the motor for diss-assembly and Re assemble it in the Frame? or did you put it in there to do the measuring and then pull it out again...

Im working on the Logistics of doing a 750 head swap with cams and Hayabusa pistons