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BIKES/PARTS/GEAR for sale/wanted / Re: '91 Bandit 400 looking for a good home
« Last post by BretSV on February 21, 2020, 12:45:36 PM »
Suvari, I am interested. I sold me 1991 400 years ago and have wanted another project since. Give me a call or text 804 833 2544 or email bret.schardein at gmail. I’m headed up your way in 2 weeks actually.
Hey everybody! I'm hoping someone out there in Bandit Land can help me out.

I've got a 2000 model Bandit 1200 (GV75A) that I bought Jan. 2019. It has a few issues but has basically run like a scalded dog (meaning very well and FAST) up until about a month ago. The current problem seems to be an over-fueling or fuel delivery problem, I'm not sure which. The other issues (rev counter/fuel gauge/Oil and Neutral lights not working) I shall tackle/address in another string.

The problem as it stands it that I can start the bike and very slowly turn the throttle up to a point, it will rev up (up to a point) and then die. If I open the throttle wide as it's idling, it dies instantly.

Back story and steps taken so far:

About a 2 months ago, I was riding without any motor issues but then I noticed a light sputtering at idle that became worse if I slightly twisted the throttle. When I turned the tap to Reserve or Prime it went away, or so it seemed at first. However the problem grew to a point where it didn't matter what I selected on the fuel tap.
So I bought a kit and rebuilt the tap. Again…at first it seemed to work but I perceived the same symptoms after a day or two following the rebuild.
And THAT’S when IT happened. After a day of riding around the city I went to my last appointment before heading home. Everything “worked”. After my appointment I mounted my bike and started her without problem. BUT…when I drove off, she sputtered very steadily and I had no power. It acted like a car with a bad distributor rotor or a burnt-through spark plug wire. So I limped her home and parked her in the garage.
It took me another month to get the time to have a real good look at the problem. My bike had been parked on the side stand the whole time. She would not start at first and it took a loooooong while to get her going. This is when the heavy sputtering and misfiring began. The slightest choke or gas would kill the motor instantly.
So my mate Chris and I wanted to check the plugs and as he grabbed the number 2 cable he got electrocuted. The spark plug cap came right off the cable effortlessly. AND the spark plug itself was not even finger tight in its place. So I thought that was the obvious problem. NOPE!
Spark plugs pulled, checked and re-seated. Screwed the caps back onto the cables but still sputtered like hell. The carbs were totally flooded. So I ran them dry the best I could in the bike’s current state, then drained the float bowls completely.
Even earlier I had installed touring bars on the bike so in case the choke was marginally open, I adjusted the choke line to give as much slack as possible without disconnecting it. (Maybe that was a mistake)
So after reconnecting the vacuum line to the carbs, I set the tap to ON and after a couple turns she fired up AND sounded better…but still sputtering a bit, though not as bad as a few hours before. BUT when I gave her a good twist of the throttle, she died. I could start her and leave the choke on now and she’d run fast and loud but the moment I turned the throttle, she died.

And that’s where I’m at now. I am not sure of my next step. Sorry for the short-story novel….but can anyone help????

Much obliged for your attention and any advice.

SUZUKI BANDIT 250 & 400 / Re: B400 choke/starter circuit not working
« Last post by Mechannibalism on February 16, 2020, 03:47:27 PM »
I think your right that the choke circuit is plugged up.  It could be the Jet/emulsion tube  or the outside transfer tube. I would blow it out backwards (from the port in the top of the carb by the vacuum diaphragm).  Squirt some carb cleaner in it and soak it over night.
SUZUKI BANDIT 250 & 400 / B400 choke/starter circuit not working
« Last post by bdouvill on February 12, 2020, 12:01:43 PM »
Hi there,

It's been a long time ;-)

I had my B400 for about 10 years now. End of 2018, it started giving me headaches so I stopped using it. At the time, I switched to my resurrected 1993 VFR 750 (that was flooded but that's another story) then also bought a 2009 ZX-10R (as a daily).

I worked in parallel on the Bandit to get it back to work. One coil failed and I replaced it with a cheap one from Ebay. Also changed the spark plugs and changed all seals of the carbs because I started getting some leaks. I previously put a Litetek kit and that was fine, but I changed again all seals with Suzuki ones plus all one sealing the carbs together. I spend around 250€ in original Suzuki carb parts, that is crazy.

Back in September 2019, I was able to restart it, used it only once and stopped since then because of what follows:
- bike does not start when battery is fully charged and fuel is obviously going to the carbs
- choke/starter system does not work at all, apparently only gives more air to the engine and no fuel - let's talk about that later
- when spraying anything in the airbox, like break cleaner, engines start and then everything is fine.
I mean:
- idle is smooth and engine is starting gently
- throttle response is good
- bike works like a charm.
BUT if I stop and have to restart it, again, it starts very hardly.
Last point:
if it runs and I start using the choke, then it dies.

During last winter, I checked the valve adjustements -there's nothing wrong here after 101000km ;-)
Carbs are well balanced - I use a Carbtune Pro II, this is fantastic.

So it's so hard to start that I basically stopped using it after running it only twice in 2019...

I can't live like with that. In fact since I have it, I rode it for 35000km approx and the choke/starter circuit never worked.
I even changed all 4 carb started seals - item #42 here:

The more I think about it, the more I believe the choke circuit is clogged. My problem is that apparently, you cannot dismantle the circuit to clean it, I found no info, no picture of that.

The closer I found is there:
2 posts from the end:
"If you take the bottom off one the carbs you'll find a plastic tubular housing the plugs into the main body and seals with little o-rings. there's a small brass jet set in the housing that meters fuel to the choke (fuel enrichment circuit actually). If this jet is blocked, you'll get no fuel when trying to start the bike on choke. My sister's bike was so clogged up there was no evidence of the jet at all and I found it by digging all the crap from the end of the plastic tube. There's one in each of the four carbs."

On mine, I am 100% sure the float assembly is not clogged at all but I have no clue for the rest of the carb(s). There's the external line on the side of the carb but I don't know if it's possible to remove it to clean it. Otherwise, all I can do is to find compressed air and blow inside each side and check it's blocked or not.

According to the service manual (page 4-9), there's a crossing between fuel that comes from the bottom and air that comes from behind the diaphragm where the starter plunger goes. From there, it goes through the starter outlet into the main bore.

Will try to remove the carbs from the bike as soon as I can and find for evidence of clogged circuit. I think the end of the choke circuit (between diaphragm, starter plunger and main bore) should be easy to check but what about the rest (from the float chamber to the starter plunger)?

Anyone can help here? I googled like crazy before asking here.
Is there anything I can do apart from getting the carbs cleaned with ultrasound?

Thanks a lot in advance for your help.
BIKES/PARTS/GEAR for sale/wanted / Re: '91 Bandit 400 looking for a good home
« Last post by suvari on February 05, 2020, 10:45:25 AM »
Hi all--this Bandit 400 is free to take for those who can transport it away. It is based in Washington DC. Let me know!
SUZUKI BANDIT 250 & 400 / Re: Greg's Bandit 400 Fuel Injection Project...
« Last post by nsc on January 21, 2020, 11:52:33 AM »
Good to hear that! Keep us postage with the engine progress if and when you decide to go on.

If photobucket doesn't work out keep in mind that there are other cloud services like google drive, onedrive, dropbox etc that they have free services.
SUZUKI BANDIT 250 & 400 / Re: Greg's Bandit 400 Fuel Injection Project...
« Last post by greg737 on January 20, 2020, 08:48:34 PM »
Hey Greg I hope you are good, any chance of setting up an online photo album of the build? All the pictures in the topic have expired sand all the visual reference is unfotunately gone!

Yeah, I'm still around, still have the FI GSF400, still riding it, the bike never fails to please me as it's such an different experience from my other motorcycles (the VFR800 and the EX250).

Recently my Photobucket account went down, not because I failed to pay for the account, I got billed in December 2019 and paid, have the credit card statement to prove it, so it's not because of money.  Instead Photobucket is claiming that they had a "server problem" and my account was "one of the affected accounts" and they say it will be back up as soon as possible.

We'll see what happens.  The GSF400 still runs great, but smokes a bit on start-up after sitting for a while (like a week or month).  Long term I'm thinking about a refresh of the engine, things like pistons and the valves and maybe the valve guides.
SUZUKI BANDIT 250 & 400 / Re: Greg's Bandit 400 Fuel Injection Project...
« Last post by nsc on January 19, 2020, 03:34:31 PM »
Hey Greg I hope you are good, any chance of setting up an online photo album of the build? All the pictures in the topic have expired sand all the visual reference is unfotunately gone!
SUZUKI BANDIT 250 & 400 / My 92 suzuki gsf250 transparent clutch cover
« Last post by chamarang on December 31, 2019, 01:59:50 PM »
Transparent clutch cover

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