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Author Topic: Bandit 400 - GSXR 750 Fork swap - Build thread  (Read 2218 times)

Offline Volumetrik

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Bandit 400 - GSXR 750 Fork swap - Build thread
« on: December 05, 2016, 02:03:03 AM »
Hey, my name is Max. I'm 22 and just got my motorcycle license in September.

So I bought a 1991 GSF 400 just after I got my license and I've been enjoying it a lot.



I have put around 800km on it already !



Since I can't let anything I own stay stock, I decided to do a fork swap.

I found a full 1995 GSXR 750 front end with brakes, wheel, clip ons, yokes, etc for 240 canadian pesos.



Brought it home, pressure washed it and replaced the fork oil, fork seal and dust seal on the forks.







I then decided to use the 750 switch housings because the plastic was in much better condition.



The connectors were not the same unfortunately, so I had to cut the pigtail and re-solder and shrink-wrap.









The front master cylinder was pretty worn out paint-wise so I sand blasted it and off to paint.





I had to drill out the old ignition cylinder retaining bolts because the PO stripped them with a power drill trying to remove them...



Next order of things is to start removing the front end.







Gauge cluster and handlebars removed.



Stripped naked





Completely removed, this was surprisingly stable and I was able to work on the bike with no fear of tipping.





Box of pieces



Wasting no time, I put on the new fork, which I already prepared in advance, cleaned and packed the bearings with new grease.





So here it is. The indefinite proof, 100% confirmed that a 1995 GSXR 750 non-srad fork swaps STRAIGHT IN a 1991 GSF 400 Bandit.





Put on the gauge cluster and clip-ons. I will probably drill the top triple to use my renthal bars in the future.



As you can see the gauge cluster is not a direct bolt in, you need to remove the metal sleeves (that sit into the rubber bushing of the gauge bracket) that the screw to the left (in the picture) goes into. This will give it more space. The 750 triple has larger bolt perches than the stock B4 one, so removing the sleeves will help gain the extra width. It's still not ideal, but for now it'll do.



Mocked up with the B4 wheel just to see a all-black look.



I will definitely paint the white gsxr wheel black. You can see it in the background.



And so it brings us here for this week at least. I won't be able to work on this for the next two weeks because of finals, but I am super excited to get the wheel sandblasted and painted.



Finally I need to get the gsxr fender paint matched. It will be mint I'm sure.

If you have any questions, feel free to ask, I read and learned so much from these forums that it's time I give back somehow.

I wish I had taken more pictures, but when your hands are all greasy, you don't want to touch your phone  :rofl:

« Last Edit: December 08, 2016, 01:03:28 AM by Volumetrik »
1991 GSF 400 Bandit : Montreal, Canada

Offline Squishy

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Re: Bandit 400 - GSXR 750 Fork swap - Build thread
« Reply #1 on: December 05, 2016, 03:57:30 AM »
Nice work. And plenty of pictures ;). I always start not wanting to touch my phone, but I do anyway (use it as flashlight/pictures). Then it's dirty anyway so I give up and it gets covered in oil/grease  :bandit:

Anyway good to see it's a 1:1 swap. Wonder how easy it is to properly fit the gauge and headlights.
I've thought about buying a gixxer front-end but never did because I think the front end of the b400 (even with stock springs) actually handles really great. Also with only 1 disc it's quite a bit lighter. I thought it would do away with the quick steering.
Though if you do it right it does look cool.


Offline Volumetrik

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Re: Bandit 400 - GSXR 750 Fork swap - Build thread
« Reply #2 on: December 05, 2016, 09:46:25 AM »
Thanks for the reply Squishy !

I'm curious now of the weight of both front ends.

When I get everything back from the paint shop and mounted, I will weigh both front ends to see the difference !

You can't use any of the previous brackets for the light. Diameter of the forks are way to large and they are further apart.

I will have to make  a custom bracket attached at the bottom of the light to the bottom triple clamp.

Cheers
1991 GSF 400 Bandit : Montreal, Canada

Offline TJS

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Re: Bandit 400 - GSXR 750 Fork swap - Build thread
« Reply #3 on: December 07, 2016, 11:05:29 PM »
Nice work! Your 6 pot calibers and that they are clear anodized, make me believe they are from a '95 gsxr 750. '94 were blue. '92 inner slide tube were smaller than the 94/95 and used 4 pot Nissan calibers.....at leat as compared to what was shipped and titled in the USA.
Squishy, If you want the standard look, but want adjustability and increase performance; '89 GSXR 750 is a straight swap.

Offline Volumetrik

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Re: Bandit 400 - GSXR 750 Fork swap - Build thread
« Reply #4 on: December 08, 2016, 12:59:07 AM »
Good observation TJS !  :thumb:

I will edit my post. The guy I bought them from told me they were from a '93.

Upon further investigation and looking at the parts diagram from partsoutlaw, it seems I have the forks from a GSXR 750 WS model.

It seems that the only difference between the R and S mode for the brakes is the pads.

The compound on mine is split in two, compared to the R model which is split in 4.

Cheers
1991 GSF 400 Bandit : Montreal, Canada

Offline TJS

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Re: Bandit 400 - GSXR 750 Fork swap - Build thread
« Reply #5 on: December 08, 2016, 09:32:21 AM »
Sorry, wasn't trying to be a "know it all" jerk. Just, I learned the hard way when I ordered new seals from K&L Supply and All Ballz racing.
The guys there were nice enough to do an exchange and now list separate part numbers for the 94/95 fork seals and brake calibers. I had to take my forks to the local Suzuki shop for confirmation and so they could act as a moderator.

Offline ventYl

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Re: Bandit 400 - GSXR 750 Fork swap - Build thread
« Reply #6 on: December 18, 2016, 06:04:27 AM »
I've already seen several B4s with USD front fork and it always seemed to me that the front end looks way too bulky. But here it looks just right.  :thumb:
Bandit 400 1991 - stock except of swap from GK75B to GK75A

Offline Volumetrik

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Re: Bandit 400 - GSXR 750 Fork swap - Build thread
« Reply #7 on: December 19, 2016, 03:15:04 AM »
Don't worry TJS, you didin't sound ''know it all'', just informative !

Thanks ventYl, my goal is a OEM+ look.
1991 GSF 400 Bandit : Montreal, Canada

Offline Volumetrik

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Re: Bandit 400 - GSXR 750 Fork swap - Build thread
« Reply #8 on: December 19, 2016, 12:27:33 PM »
Round 2 ITS LIT

The day started with rebuilding the front master cylinder with new OEM parts.



I also installed tygon tubing for the reservoir. It's very resistant and durable.



Next I bent back the headlight brackets to fit in between the two forks.







And cut the adjustment bracket off. I wish I could keep it, but it prevents the light from fully seating back.



Head light with both brackets bent.





Next up I marked the bottom triple to drill and tap with 6mm bolts.







I also cut two steel 9.5 inch by 2 inch rectangle brackets. Each end will be bent 90 degrees at the 1 inch mark. These will go vertically in-between the top and bottom triple. I installed the bent brackets and marked where the headlight holes would go. I then drilled and taped them.





All cut and installed. It's a tight fit and I will need to trim the brackets, but it fits !





Tight on the ignition barrel ! It goes without saying that I will be using aftermarket 2.5 inch gauges because the stockers are way too big.



Trimming the brackets.







Installed. They look sweet as hell. I'm very happy with the result.









Overall look with the headlight installed.







That's it for this weekend ! Next up will be making brackets for the turn signals and installing the grips, both switch housings.

I will have to work out the extra length of the clutch, throttle and choke since the handlebars are lower than stock.

The front fender is at the painters and I will be painting the front wheel flat black very soon. I'm hyped, the bike looks so badass with the dual front disks.
« Last Edit: December 19, 2016, 12:31:02 PM by Volumetrik »
1991 GSF 400 Bandit : Montreal, Canada

Offline bdouvill

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Re: Bandit 400 - GSXR 750 Fork swap - Build thread
« Reply #9 on: December 21, 2016, 12:29:55 PM »
I like the way you designed your plates to hold the headlight. :congrats:
Benoit.
Bandit 400 1992, 1st bike.

Offline Volumetrik

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Re: Bandit 400 - GSXR 750 Fork swap - Build thread
« Reply #10 on: December 23, 2016, 02:56:38 PM »
Thanks bdouvill !

They are not as solid as I want, so I will probably add a cross brace soon that will double as a headlight adjuster.
1991 GSF 400 Bandit : Montreal, Canada

Offline Volumetrik

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Re: Bandit 400 - GSXR 750 Fork swap - Build thread
« Reply #11 on: May 28, 2017, 01:10:34 AM »
Round 3 let's GOO

Sorry for the long time, some of these pics are from february and march, but everything is on track.

Got the fender back from paint and it looks mint, pics further down.

Started by masking the headlight, sandblasting and painting.








Decided to make a dedicated turn signal bracket. In the end, I did not end up using it.








Little welding station besides the ST.




Went and installed the clip-ons from the 750 but quickly discovered that the clutch cable was WAY too long. I could not bend it to fit, unfortunately. You can see it stick out like a sore thumb.






So I went with the next logical thing.










Handlebar conversion !

Needed to do some clearancing before bolting everything back together.






Then did some paper assisted design.












Ended up with a bracket for the speedometer. Right now I am planning to run only a speedo and no rpm. I may change ideas, but I can't find a gauge that has 14k rpm and electrically operated that looks half decent.




Now that everything is re-enforced and solid, I did a test fit to see how everything lined up.






The height difference is quite staggering. The riding position is also much more comfortable. All the cables are happy too. Nothing is bent awkwardly and everything is snug. It looks quite good too, very street fighter-ish. Also positioned the speedo in place. Clearance is very tight with the current brackets. I have since redone these and the fit is much better.








That is the clearance I was talking about.




Painted the wheel flat black with Rustoleum Professional. This stuff is great.




This is how the bike sits as of now.











Here is a sneak peek of round 4  :bandit:




That's it for now. I did also a couple of things off camera, like changing the throttle cable, ordering custom length brake lines from HEL and re-doing brackets over and over again  :roll:

But everything is good. I took the bike for a quick ride and  my god the double caliper brakes are monstrous. I can probably flip the bike if I wanted too  :yikes:
« Last Edit: May 28, 2017, 01:14:04 AM by Volumetrik »
1991 GSF 400 Bandit : Montreal, Canada

 

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