Bandit Alley

MODEL SPECIFIC => SUZUKI BANDIT 250 & 400 => Topic started by: PUGLIA on July 06, 2013, 01:30:52 AM

Title: New 400 project
Post by: PUGLIA on July 06, 2013, 01:30:52 AM
Ok so I bought a 92 400 and I found this bike. Most of it I can tell what has been done but I thought I would post this to see if any of you know how they have cleaned up so much of the middle of the bike. Battery i got it but any Ideas about the rest. This bike is beautiful and I want to do this to mine. Also does anyone know if those are stock forks looks like a front end swap but I'm not sure. Any help would be appreciated.

Here's the link

http://i2.wp.com/dogsville.es/wp-content/uploads/2011/09/bandit-400.jpeg?resize=500%252C333 :stickpoke:
Title: Re: New 400 project
Post by: nos on July 06, 2013, 05:22:30 AM
wow!!!
Title: Re: New 400 project
Post by: SoEazy on July 06, 2013, 06:41:07 AM
Very nice. As far as the center of the bike... They removed the air box and relocated the battery. Plus the seat they fabbed also creates more negative space. It looks like the frame has been detabbed and passenger pegs and mounts have been removed. Those rear sets really open it up too. Those look like stock forks just powder coated. Sick bike.
Title: Re: New 400 project
Post by: PUGLIA on July 06, 2013, 09:47:36 PM
Well I just bought a 92 for 450.00 with 9200 mi on it. Great deal bout to fire her up. Thanks for the input. I figure they tucked quite a bit up under the tank. I didn't realize that the baffle went so far up until I pulled the tank off last night. The forks are stock I just noticed that they lowered the  front end about an inch. It is a sick bike. Hopefully mine will look similar soon.
Title: Re: New 400 project
Post by: phoenix on July 07, 2013, 11:15:19 PM
Bandit 250, Japanese spec by the looks of it.

I was tempted to duplicate it a while back and this is what I came up with.  Frame has been cut about 1.5-2" after the rear joint with all unnecessary tabs removed.  Probably a 4 cell A123 battery under the seat cowl.  Seat and cowl custom using the original seal pan.  Battery box removed.  Coolant overflow is custom and sitting above the rear of the motor.  Air box removed and running no filters.  Rear sets are custom made from 3/8" steel tube or round stock.  Stock headers cut down with generic muffler.  Aftermarket clip-ons mounted under top clamp.  Aftermarket front master and reservoir.  Aftermarket speedo or tach.  I'd like to think it's a dual gauge, but probably not.  4-5" headlight.  Cut down 70s era metal front fender.

I was very tempted to do it, but I cut the tail off of a bandit 400 while I was in Japan and never could get used to the bob-tail look. 
(http://p1.bikepics.com/2005%5C08%5C11%5Cbikepics-407368-800.jpg)
(http://p1.bikepics.com/2005%5C08%5C11%5Cbikepics-407369-800.jpg)
Title: Re: New 400 project
Post by: Sean on July 08, 2013, 03:24:20 AM
I've seen that picture before... I'm not entirely sure what it us though. Engine side covers look weird.
Title: Re: New 400 project
Post by: Sean on July 08, 2013, 03:29:37 AM
At one point I really wanted to replicate that mirror placement.
Title: Re: New 400 project
Post by: PUGLIA on July 11, 2013, 05:20:56 PM
Ok well I got some parts ordered. Turn signals, clip ons, levers, grips and mirrors. Got a stock replacement air filter and oil filter, going to clean the carbs and get her running. Next will be headlight, front master & resi. will custom make a seat pan and water res and Won't mess with the tail sectio till I can set back the money for a pipe, filters and jets. Going to scrounge around for a 70's honda fender.  I'll get some pics as soon as the parts come in. I'm going with satin black chrome with burnt orange marbled over black accents! Won't be breaking her down for paint most likely till most all mods are done. Probably early winter. This is gonna piss my wife off so bad!!  :motorsmile:
Title: Re: New 400 project
Post by: PUGLIA on August 07, 2013, 03:55:33 AM
Here are a couple photos of the bandit. Still working on getting her running but think I got it narrowed down. Anyways I thought I would start posting some photos cause I hope the transformation will end up going fairly quickly.

(http://i1335.photobucket.com/albums/w673/OWAIDAT/image_zps5b2355e2.jpg)

(http://i1335.photobucket.com/albums/w673/OWAIDAT/image_zpsff28348f.jpg)

Hope the pics show
Title: Re: New 400 project
Post by: Sean on August 07, 2013, 03:52:27 PM
Pod filters look way cooler than those sidecovers
Title: Re: New 400 project
Post by: PUGLIA on August 16, 2013, 06:35:39 PM
Ok so I got the New caps in. Hopefully this will solve the problem.
(http://i1335.photobucket.com/albums/w673/OWAIDAT/DEE1174E-897F-4675-BAE5-D242C4CEB182-43933-0000027911B6BF00_zps713748fe.jpg)
(http://i1335.photobucket.com/albums/w673/OWAIDAT/C3E7FAD8-7775-4373-84F9-282A038D1E28-43933-00000279407F170A_zpsb23c9cd1.jpg)
(http://i1335.photobucket.com/albums/w673/OWAIDAT/D00D6CB8-C3C0-4D35-98C0-8125CBF5072E-43933-000002795FA5D03A_zps76830780.jpg)

Also got all the parts in. Can't wait to see how their going to look on.
(http://i1335.photobucket.com/albums/w673/OWAIDAT/EA0B8030-ABD4-4B87-BEE9-423EEBEDCE82-43933-0000027C77B38604_zpsf1e69f00.jpg)
Title: Re: New 400 project
Post by: Sean on August 17, 2013, 12:07:54 AM
I was always under the impression that the cdi box was full of magic black smoke that was carried to various parts of the bike through wires, because when it breaks you can see that vital magic smoke escaping...

Cool to see the inside of the cdi though.
Title: Re: New 400 project
Post by: PUGLIA on August 17, 2013, 12:43:57 AM
Lol! It could very well hold magical secrets still I know nothing about. I'm just following anceint thread knowledge passed down from the brave men who dared to open it before me.

Hell I just cut the thing open and soldered caps where they said to?? We'll see if it works. Couldn't be any worse than it was.
Title: Re: New 400 project
Post by: yoda on August 17, 2013, 06:07:39 PM
I've got that rizla blue bandit as my laptop wallpaper already! Hows yours going, got it started at all yet? If I leave mine long term it takes a lot of cranking to get her to catch. This last time I had to get a new battery and fully charge to last long enough. Once shes running she goes first time every time though. I was wondering about orange and black colour scheme too
Title: Re: New 400 project
Post by: PUGLIA on August 17, 2013, 06:30:01 PM
Well I got the CDI soldered up but I haven't had the chance to put it on and try it. I need to bring the bandit home. It's actually at a buddy's house who helped me out with the carbs which were a nightmare. So.... When I get the chance to go by there and get the CDI on I will load her up and bring her home. Looking forward to cutting and modding.

As far as the paint scheme I have a gallon of burnt orange that I have for my jeep I plan on using for a combination of thick and thin stripes. I thought about doing a marble effect over satin black. Maybe a thick solid with thin marbled on the outside.  Basically you spray your base of whatever color( black) and mask off your stripes or design. Spray on the color and then imediatly place saraan wrap on it and scrunched up. This will produce a marbled effect that brings the base through. Pull off the saraan wrap then apply the clear. It's pretty cool looking if done right. Still kicking around ideas.
Title: Re: New 400 project
Post by: TJS on August 17, 2013, 09:33:08 PM
Wish I knew more about electrics! You have a "How to..." on youtube?
Title: Re: New 400 project
Post by: Sean on August 17, 2013, 09:43:52 PM
All I know is when you see that black smoke escaping, it's broken.
Title: Re: New 400 project
Post by: PUGLIA on August 17, 2013, 11:16:50 PM
All I did was follow the instructions from DIY CDI repair in the 250/400 FAQ section of this forum. Here:

http://forums.banditalley.net/index.php?topic=431.0

It was pretty easy to do. But I will go into a little better detail after I test it and see if it worked, lol! I would hate to give messed up advice. I haven't soldered since I was a kid and it was pretty easy.

Title: Re: New 400 project
Post by: wario on August 18, 2013, 08:53:25 PM
All I did was follow the instructions from DIY CDI repair in the 250/400 FAQ section of this forum. Here:

http://forums.banditalley.net/index.php?topic=431.0

It was pretty easy to do. But I will go into a little better detail after I test it and see if it worked, lol! I would hate to give messed up advice. I haven't soldered since I was a kid and it was pretty easy.



I did mine twice. The first time with Radio Shack crap caps- then, I ordered some commercial caps on line that had a much higher temp rating. They worked great. Both sets lit off on the first push of the button... but, the RS caps died within a week.
Title: Re: New 400 project
Post by: PUGLIA on August 18, 2013, 10:21:22 PM
Thanks for the info. I got mine at radio shack. So where did u go online to get the caps?
Title: Re: New 400 project
Post by: wario on August 18, 2013, 10:30:14 PM
Thanks for the info. I got mine at radio shack. So where did u go online to get the caps?

I'll check for my receipt - basically, they're sound amplifier grade and able to withstand high temps...
Title: Re: New 400 project
Post by: PUGLIA on August 21, 2013, 05:37:04 AM
Ok well I'm a little dissappointed. I tried the CDI and I still have no spark. I didn't have a lot of time to work on it but I hooked it up and still got nada. Sooo I guess I'm going to have to go back and test to see where the problem is. I don't know for sure what the ohm readings should have been. Probably should have asked before I broke into the CDI and ran my test the first time. Does anyone have a breakdown of what readings I need and where? For instance
Coils-plug wires- pick up coil- ect. So that I can try and hunt down the problem. I'm not the best at reading wiring diagrams and the copy I have I can't really make out the numbers on it anyways. Any help would be appreciated.

And Wario if you could get that web site I would appreciate it.
Title: Re: New 400 project
Post by: bdouvill on August 21, 2013, 11:36:52 AM
Hi Puglia,

Saw the pictures oh handlebars and levers. I got the same, both from Ebay directly from China (see here: http://img98.xooimage.com/views/0/0/e/photo0266-3e669c4.jpg/).

I'd just want to warn you about the clutch lever. Mine completely ruined my clutch cable in less than 1000 km (like 600 miles). Problem comes from the location where the cylindrical head of the cable is inserted in the lever: there's a sharp edge at the junction with the cable. It is not really in contact with the cable when the lever is not pulled, but anytime you pull it, the cable will touch this edge and get damaged.

The standard lever is not machined the same way, the part where the cable goes into the lever is machined deeper, so it does not come in contact with the lever when you pull it.

I hope this can help anyone getting is clutch cable ruined. I did not solve this problem yet, just replaced the lever with the old one (not really good-looking, this is why I bought the nice one) when I had to buy a new cable. Anyone here that experienced the same problem?

Thanks.
Title: Re: New 400 project
Post by: PUGLIA on August 21, 2013, 02:38:43 PM
Thanks for the info. I'll make sure I keep that in mind. Problem is I gotta get it running before I can even use the clutch.

Your bike looks good. I like it
Title: Re: New 400 project
Post by: wario on August 22, 2013, 02:41:21 PM
Thanks for the info. I got mine at radio shack. So where did u go online to get the caps?

I'll check for my receipt - basically, they're sound amplifier grade and able to withstand high temps...

I found the site - its http://www.parts-express.com

Good folks, fast shipping, great parts.
 :thumb:
Title: Re: New 400 project
Post by: PUGLIA on August 22, 2013, 02:52:27 PM
Hey wario where are you from?  Thanks for the site I will check it out.
Title: Re: New 400 project
Post by: wario on August 22, 2013, 04:24:55 PM
Hey wario where are you from?  Thanks for the site I will check it out.

Grand Rapids Michigan.
Title: Re: New 400 project
Post by: Mechannibalism on August 22, 2013, 07:05:42 PM
Where do I start :~)  Get yourself a good digital voltmeter and a small 12 volt test lamp (I use a 1156 auto bulb) .  Unplug the Ignitor and test the all the wiring at the plug, Use the bulb for checking power  because the bike sat for so long  and the switches and connectors can be grungie and even though they check fine with a meter they can't pass enough current to work properly.  I have learned this from working on boats around salt water.   The check list: kill switch, Ignition Sw. ,Negative side of the circuit, fuses("ignition/fan") pickup coil. I'm not sure if your bike has a side stand kill Sw.
Title: Re: New 400 project
Post by: Mechannibalism on August 22, 2013, 07:14:06 PM
 And check that there is power to the coils ,each coil has a common 12v+(orange?) from the Ing.Sw. and seperate wires to the Ignitor
Title: Re: New 400 project
Post by: PUGLIA on August 23, 2013, 01:44:51 AM
That's a great idea about the light bulb. I will check it out  :thumb: I got a hit on another 400 and its a complete bike I can get for 100 bucks. I should have plenty of parts and can pick the best of both bikes. I think Im going to get mine running and break down the other bike. That way i can cut and make all the mods to the frame and powder coat the frame of the parts bike wheels and swing arm while im riding mine. Also if I want to try a fork swap or swing arm swap I can fit it all on the second frame and ride until im ready to put it all together.