2001 Bandit GSF600sk vs. Deer Rebuild

[Rotten Ronnie]

When the bike went down it snapped off the left side footrest bracket.

I bought a new one and salvaged the rubber and metal bushings, but had to replace one as it was out of round. I cut them out of the bracket with a dremel tool, but found that the fit was extremely tight and was unable to mount them into the new bracket by hand.

Does anyone have any advice to offer for DIY?

My other option was to take the parts to a place that presses in bearings and let them have a go.

Part number three is what I'm describing...

[Rotten Ronnie]

I got a couple of good ideas on another board so I thought I'd share them with you here.

One is to warm the bracket up in a 300 degree oven while placing the bushings in the freezer for a period of time, then you have cold contracted bushings, and warm expanded bracket. Insert bushings and allow the parts to return to room temperature.

The other involves a threaded rod, some washers and nuts. You spin a nut and washer on the end of the rod and pass it through the bushing and through the bracket where you place the second washer and nut. Now tighten the nuts applying pressure to washers forcing the bushings to seat. Alignment is going to have to be watched carefully in this method.

Hopefully I'll be able to report some progress.

[pmackie]

Both those options sound like possibilities...the other way involves a hydraulic press.

[Rotten Ronnie]

I was down at Riders Choice in Toronto having them take a look at my front forks and they pressed in the bushings for a nominal fee while I waited.

The bracket and foot peg assembly is back on the bike, but I had a bugger of a time getting the new gear shift rod threaded onto both the nuts and ends. I ended up using a die to retap the end threads and that helped "git r done".



The fork tubes are done in.  Does anyone know where I might find a set of used or new tubes? I was quoted about $400 dollars Cdn for two new tubes from Suzuki.

[r_outsider]

You could try a wrecker like these guys

http://www.bikeyard.com/

Unfortunately, I think you're probably going to find most wrecked bikes have the same problem with the forks as you, and the ones that don't might be reluctant to separate them into parts. The good news is that you could take this opportunity to upgrade to some GSX-R forks, or if you'd like to stick with stock, I'm sure there are plenty of B6 and B12 forks around from others doing upgrades themselves. I've also heard of some people getting their tubes straightened at various bike and hydraulic shops. Not sure if it's possible with yours, but you could always ask.

[mwheat308]

I have straightened two sets of forks over the years, I rode both bikes after, for several months each.
I will say that I was just never comfortable with them and sold both bikes. ( yes I told the buyers )
A machine shop with a press can do the job for you if you decide to go that way.
Mike

[Rotten Ronnie]

The forktubes are kinked and they can't be fixed, so I've been told.

What would be involved in swapping fronts? I suppose I'd need a new front rim and calipers to match the Gsx-r front end? Spacers? Would I need to replace the triple trees as well?

[r_outsider]

There's been a few people on this very forum who've done the swap-search it up and you'll find some pretty useful info. Mademiriam's Hayabusa swap immediately comes to mind. I would think the easiest way would be just to get the whole works and swap it on from there, rather than trying to piece things together, but I've never had to do it.

[Rotten Ronnie]

IT'S ALIVE!!!



At long last I found a pair of forks on fleabay and dropped them in. I got it insured and replated a couple of weeks ago and just got back from a 1200 mile trip down into Pennslyvania and New York this past weekend. It runs like a top after sitting in the garage for four years. Dang this thing is fun to ride!

Bandit rat bike...

Here's what happened to it four years ago:

http://tinyurl.com/3o3hdql

[banditv]

good to see both you and the bike came right.
i have the exact same alpinestar boots, just in a size 47.

[Rotten Ronnie]

good to see both you and the bike came right.
i have the exact same alpinestar boots, just in a size 47.

Lol. I was wearing them again last week in Pennsylvania, they took a beating and are still waterproof with the Goretex lining. They make great spring fall boots.

As far as the bike goes, I swapped in my progressive springs and the mushy, bottoming front end feels miles better. Sunday I picked up some Schedule 40 PVC pipe for spacers, and I'll add even more preload so it corners like it's on rails. I already have a KLR that has 8 inches of travel thanks. :P

[Rotten Ronnie]

Guys, I want to add some bar risers to take the bars back and up, but continue to use stock cables. Any suggestions? Brands? Links?

Can I use Suzuki dirt bike risers like those made by Zeta?

http://aviciouscycle.ca/mainpages/productpage.aspx?productid=385

[Red01]

Guys, I want to add some bar risers to take the bars back and up, but continue to use stock cables. Any suggestions? Brands? Links?

Can I use Suzuki dirt bike risers like those made by Zeta?

http://www.aviciouscycle.ca/klr009556.html

Your link and image didn't work for me, but I did find the Zeta risers on their site here: http://aviciouscycle.ca/MainPages/productpage.aspx?productid=385

I'm not sure about the 600, but on the 2G 1200, there's not a lot of extra slack in the front brake hose to handle much of a riser.  But take it from me, there's a world of front brake improvement if you dump those rubber hoses (if they're still OE, they're overdue for a change anyway) for steel braided lines and most of them have enough extra length to handle different bars and/or risers.
(I don't have risers on my Bandit though.)

Here's another style:
http://www.holeshot.com/old/Bandit/bndt_handlebar_riser.html
Check with them to be sure the hoses with their kits will work on your 600 - or if they can make you up a package that'll work.

If you can find someone with a 1G 600 or 1200 who isn't using their OE handlebars, you may be able to pick them up free/cheap - or perhaps a trade.  They are a little taller and should work without changing anything.

[Rotten Ronnie]

Eric updated his website, I just fixed the links, thanks.

The holeshot kit looks great, although I found some Dirtly risers on eBay for $37 dollars before shipping that I'll try:

http://www.ebay.ca/itm/1-HandleBar-Risers-Suzuki-Bandit-GSF600-GSF1200-K-/270352540152?pt=Motorcycles_Parts_Accessories&hash=item3ef24461f8#ht_500wt_668

Thanks for your input.

Update: the stator cover gasket is gone and she's beginning to mark her spot and my boot. It's sidelined until I can obtain a gasket, oil and filter. Poor Bandit.

[Red01]

Update: the stator cover gasket is gone and she's beginning to mark her spot and my boot. It's sidelined until I can obtain a gasket, oil and filter. Poor Bandit.

You can remove the gasket and use a silicone sealant, like Permatex or other similar product, instead.
Then you don't have to be sidelined very long.