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Project The 45hp project, GJ74A

Discussion in 'Your 250cc Projects' started by amct77, Mar 20, 2023.

  1. amct77

    amct77 the one that got away......

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    2002 suzuki sv650s, bandit 250p, bandit 250nr, bandit n, bandit 90
    After buying three bandits for cheap and finding a myriad of issues, bandit number four seems to be the best choice to get on the road quickest.



    So far it seems all I have to do is get number 2 cylinder sorted and the motor is tickety boo.

    Handle bars and paint work aside, I haven't found any other issues to get her on the road.


    IMG_20230320_135247_827.jpg IMG_20230320_135301_341.jpg IMG_20230320_135313_006.jpg
     
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  2. amct77

    amct77 the one that got away......

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    Swapped the right coil with another I had and got heat out of the headers.
    It seems that the previous attempt to fix the problem didn't work. When I unscrewed the plug from cylinder two lead I couldn't see any core (wires) .
    Next step is to get the handle bars on so as to ascertain if the coils and plugs are getting enough current to start on choke when cold.

    I foolishly bought a set of coils of eBay and then found a set in a box that I could try to use. Trimmed the lead, screwed the plug back on and hey presto cylinder two header now generates heat.
     
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  3. amct77

    amct77 the one that got away......

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    My Bike:
    2002 suzuki sv650s, bandit 250p, bandit 250nr, bandit n, bandit 90
    Got some parts delivered during the week and with the carport having a free space today, I hooked in.
    Handle bars on with controls and grips, the id of the bars won't let me fit in some bar ends I have laying around; so ad that to the shopping list with some bigger grips.
    Kicked the motor over and after some fluffing she started up, more fuel needed in the tank and the spare carbs should be sent off for a a deep refurb and paint...... One day. Cylinder two header is still getting hot and no more rough vibrations when idling and reving.
    Started pulling off the peg hangers to replace with some unpainted ones and better pegs.... Ordered the wrong ones! Pegs are for the 600 bandit and up. Lesson one: don't buy parts online when I am in a rush and under the influence. More on the shopping list.
    The rad guards were painted black and looked crap, so I found some half decent ones and a mesh guard. Lesson two: remember the don't force thread rule to avoid cross threading.
    When swaping the right rear peg pracket I noticed the exhaust can bracket has been bent in, probably from a fall, but that's ok I have a spare off that too. Will need a polish up though. If funds permit a keracote would be nice.
    Stole a pair of cheap knock off mirrors off another bandit I was working on. Now it's starting to look like a complete bike.
    Sat on the bike and got a feel of the grip to peg ratio and It feels good. Confirms a decision to swap the forks for bandit 400 ones so I can have better suspension upgrades and also fit a set of five spoke rims I like. Simple slot in job, but the money for the upgrade will have to wait.
    A bit let down with the indicators I got, the thread isn't long enough to fit through the headlight like on a standard bike. The hole drilled behind it will have to do until I can find a better pair. IMG_20230331_135859_288.jpg IMG_20230331_135919_767.jpg
     
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  4. amct77

    amct77 the one that got away......

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    My Bike:
    2002 suzuki sv650s, bandit 250p, bandit 250nr, bandit n, bandit 90
    Asking for advice and opinions on the next part of the project.
    I want all these peg hangers to be bright polished.
    I have no idea what process the factory had them at and I have seen a you tube of the gj74a ones bright polished with a sort of brush finish.
    To be original I'm going to see if the gj77a hangers fit on my beautiful bandit. There will be some grinding to fit but if the holes don't line up I won't go any further.
    Liking to do as much of the job myself so, what recommendations does the forum have?
    IMG_20230404_164150_972.jpg
     
  5. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    A small soft wire brush in a Dremel or similar tool gives a near factory finish.
     
  6. amct77

    amct77 the one that got away......

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    Cool, thanks.
    I have a dremmel.
    Do you think I could polish it with a battery drill or would a dremmel be better.
    Oh and thoughts on clear coat to slow down erosion?
    And aqua blasting? There is a business nearby that look like they do good work.
     
  7. amct77

    amct77 the one that got away......

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    My Bike:
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    Quick experiment and hey presto, looking good for a custom job. IMG_20230404_184256_116.jpg
     
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  8. amct77

    amct77 the one that got away......

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    My Bike:
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    And this one too. Helps justify a custom exhaust IMG_20230404_184529_149.jpg
     
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  9. amct77

    amct77 the one that got away......

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    My Bike:
    2002 suzuki sv650s, bandit 250p, bandit 250nr, bandit n, bandit 90
    So I was feeling a bit down not having the energy to do anything.
    Started drinking in my carport and looked up on eBay on what tools will need to polish stuff.
    Bought some things to do an exhaust and looked at my collection of "things" and found a dremmel, some buffing wheels and a tube of autosol for aluminium.
    Thinks, stuff it have a craic and tried to have a go at polishing my peg hangers.
    Got half way through and realised I was taking off clear coat, but the Bundy rum had kicked in and I kept going.
    I was having a ball until the noise police told me they could hear the dremmel going at 9:30pm.
    But we live on property?
    Any hoo, this is as far as I got. Bring on day light! IMG_20230409_215307_111.jpg
     
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  10. amct77

    amct77 the one that got away......

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    Update.
    I was using autosol aluminium polish with a felt tip dremmel but I wasn't getting the result I wanted.
    So I ordered an eBay set of scotch Brite tips to take the paint off and these are the results.
    IMG_20230418_201846_317.jpg
    The left side is atutosol only and the right side and guard s a mixture of scotch Brite and autosol.
    All the scotch Brite made really bad indents in the alloy. I was hoping that the different colour options in scotch Brite would be different grades like sand paper, but no joy.
    At the rate I am going it seems that the autosol option only gives the brightest shine without the deep scratches or guages.
    I don't know of a dremmel attachment that is the same as a high grit number sand paper that can give me a smoother finish as I have done with autosol, so I don't know how to fix the error I made with the scotch Brite.
    Thankfully I have more foot peg plates in my arsenal so I think I will save up and get them aqua blasted and then polish with felt tools from there.
     
  11. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    I was prepping to remove some rust and mill scale the other day and came across this, didn't even realise I'd bought one.

    https://www.bunnings.com.au/josco-125mm-fine-poly-flap-disc_p6320835

    Ended up using it on some motorbike rims that has been previously polished of their paint around the circumference and allowed to accrue corrosion that I thought would be heaps of work.

    They came up shiny, using a 5" sander polisher on a slower speed, using the edge in a linear fashion around the rim circumference, works a treat, it does remove miniscule amounts of material, so takes a deft touch.

    You'd still have to do crevices and nooks with something small
     
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  12. jmw76

    jmw76 Well-Known Member

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    Yep. Flap discs are great for all sorts of things.
     
  13. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    I felt like I'd made a magnificent discovery, now I'm seriously considering polishing the wheels back to their former glory, these ones are so mild, they're not actually an abrasive, it's like using 1000 grade wet and dry.
     
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  14. amct77

    amct77 the one that got away......

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    My Bike:
    2002 suzuki sv650s, bandit 250p, bandit 250nr, bandit n, bandit 90
    I was able to afford some more bits and bobs and after they all came delivered, I'm now having fun.
    Most of the parts were bolts and washers to replace wrong and rusty ones, some missing ones too.
    Found a good replacement for the idiot lights and it's a vast improvement.
    IMG_20230526_115955_408.jpg
    See the tasty bolt plugs?
    IMG_20230526_120209_707.jpg
    I experimented with this polish on the exhaust I was going to replace. Polish good, exhaust bad. Too many scratches and gauges to fix up. The original exhaust has a bend at the hanger but much less damage on the can. Debating whether to take it off to polish. Common sense says it will be easier to get into the nook and crannys.
    Also plucking up the courage to use the paint stripper on the peg hangers and then polish after.
    I know what will fix that........ Alcohol!
     
  15. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    Nice. Where did you get the bolt plugs as I need some.
     
  16. amct77

    amct77 the one that got away......

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    Impex from japan.
     
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  17. amct77

    amct77 the one that got away......

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    My Bike:
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    Project jumbuck has gotten priority as I am getting closer to my licensee.
    Found out that I can still up grade to unrestricted while on probation, so project SV curvy is getting seeing to as well.
    But.....

    Since I was too scared to try the paint stripper, I forked out for two rider pegs and tried take 2.
    This time it will be autosol and cloth buffing wheel only as I feel I butchered a good job with scotch wheels.
    Speaking of scotch, this post is sponsored by a friend who supplies me with cheap scotch to get things done.

    As this model has been registered as a single seat, I am saving up for a bandit 400 rear seat cover to stay solo

    Still deciding whether to modify frame to fit my vg22 arm or go with a gsxr 400 swinger.

    Up front will be a usd as I have triple trees that will slot in without bearing or stem mod.

    Stay tuned in 2024 for more updates
    IMG_20230727_175725_132.jpg
     
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