Author Topic: GR400's 400. First timer restoration  (Read 17617 times)

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Offline betty foRD

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Re: GR400's 400. First timer restoration
« Reply #90 on: March 09, 2019, 01:54:12 PM »
Here's my secret weapon - remember rule is nothing older than 1979! so you can't bring out that Kawasaki.

Weapon? What like a doodle bug....only goes in a strait line and reaches ‘final destination’ when the engine cuts out !

(Quite fond of the kettle but this is a RD forum  :D)
« Last Edit: March 09, 2019, 01:56:43 PM by betty foRD »
Rev 'em till they rattle

Offline Poutie

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Re: GR400's 400. First timer restoration
« Reply #91 on: March 09, 2019, 01:58:29 PM »
Sadly I have to agree the keys I tend to prefer are those of the rd350b :)
Dave

Bikes
Yamaha rd350b
Suzuki GT750b

Offline SteeleRD

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Re: GR400's 400. First timer restoration
« Reply #92 on: March 31, 2019, 06:56:26 PM »
looking superb mate :)
30 Year Old Two stroke enthusiast
RD250C 1977 - RD250LC
http://www.aircooledrdclub.com/smf/index.php?topic=58574.0

Offline GR400

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Re: GR400's 400. First timer restoration
« Reply #93 on: March 31, 2019, 07:35:20 PM »
Thanks.  Getting a bit more done at the moment, so I'll do another update soon
'80 RD400F, coming together slowly
'75 RD350B, my retirement project at this rate!
'01 ZRX1200R
'01 GSX-R1000 K1

Offline GR400

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Re: GR400's 400. First timer restoration
« Reply #94 on: April 02, 2019, 05:38:10 PM »
Another 4 months gone!  Not sure where, but work, Christmas and getting the ZRX fettled for the season all played a part.  Anyway, a bit of progress:

Stator came back from Rex’s Speed Shop with low speed side rewound and new harness & connectors.  Just need a dial gauge now to time her up:



Meanwhile I collected together brake parts and sourced what was missing:



Calipers were fully refurbished by Nick Chambers a couple of years ago when he did my wheels, so they could finally see the light of day.  More recently Nick also did the rear master cylinder for me and supplied the black sheathed braided front hose.

Front master cylinder is NOS, a nice find some time ago, and the original levers were undamaged and cleaned up nicely.

I think it’s been said before that NOS paint wasn’t up to much!



And my switchgear was pretty rough:



So I stripped them all down, and stripped the paint along with the clutch perch:



After a few sessions with etch primer, regular primer and satin black they looked much better:



So master cylinder reassembled with lever and on the bike, along with clutch perch and lever:



And mated to front caliper, just waiting for fluid and bleeding.  It’s all refurbed or new so I’ve got my one-time choice now between DOT4 and DOT5.  Still making up my mind:



And here’s the rear, all together with new hose:



The rear reservoir came up well after a cycle in the dishwasher, and I think the red reservoir hose and spring are good enough to go again, but I’ll do that when the electric plate is on.

Next, electrics, clocks and switches  :)

'80 RD400F, coming together slowly
'75 RD350B, my retirement project at this rate!
'01 ZRX1200R
'01 GSX-R1000 K1

Offline nerradw

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Re: GR400's 400. First timer restoration
« Reply #95 on: April 02, 2019, 06:17:13 PM »
Hi GR400
I elected to use DOT 5 as most of the rubber parts of the braking system were replaced. So far all has been working well and any leaks have no effect on that new shiney paintwork. I should add that the reservoirs have had the new fluid in them for 8 months and  the bike has covered around 150 miles since the rebuild.
I am using "OKE" DOT 5.
Nerradw
« Last Edit: April 02, 2019, 08:56:28 PM by nerradw »
🐵 Rd400c

Offline 5port

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Re: GR400's 400. First timer restoration
« Reply #96 on: April 02, 2019, 07:16:02 PM »
Thanks for posting the pic of the low speed coil rewind, first time I have seen the result.  Do you mind saying the approx cost?

5port
5port

Offline Comms Guy

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Re: GR400's 400. First timer restoration
« Reply #97 on: April 02, 2019, 08:28:01 PM »
Well done Gaz, at this rate she'll be at the Golden Anniversary club rally :P :P :P

Offline GR400

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Re: GR400's 400. First timer restoration
« Reply #98 on: April 02, 2019, 10:24:45 PM »
Darren, thanks I am leaning towards DOT5 part because its safer if it leaks and part the longevity.

Chris, £90 + VAT for the rewind, £45 + VAT for the new loom.

Paul, thanks mate, I'm tempted to bring it to this year's rally finished or not  :D

'80 RD400F, coming together slowly
'75 RD350B, my retirement project at this rate!
'01 ZRX1200R
'01 GSX-R1000 K1

Offline SteeleRD

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Re: GR400's 400. First timer restoration
« Reply #99 on: April 02, 2019, 10:40:55 PM »
Looking good!
30 Year Old Two stroke enthusiast
RD250C 1977 - RD250LC
http://www.aircooledrdclub.com/smf/index.php?topic=58574.0

Offline GR400

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Re: GR400's 400. First timer restoration
« Reply #100 on: April 28, 2019, 04:23:52 PM »
A quick update.  In the last post, switches were stripped and bodies painted.   Looms were in quite poor shape, but I had bought another set of switchgear a couple of years ago that someone had had a go at refurbing.  Bodies were powder coated and looked lumpy and horrible, but looms and kill switch on them were very good so I cannibalised them and made up a good set.  All done, with new decals:



When I bought the bike the speedo had a damaged rim and very faded face, and the tacho was from a C model, so I had one of those very rare 2 neutral light bikes!  Kept my eyes open over time for good well preserved replacements and ended up with a couple of decent sets.  The ones I am using are really nice and unfaded, with undamaged glass and rims, but paint on rims was wearing thin so prepped them for a refresh:



All done:



Pilot box was all good and undamaged, just needed a clean, I had a clock mount bracket powdercoated when the frame was done, and I painted the clock cups a long time ago when doing some other satin bits.  So here’s everything ready to go together with nice shiny new chrome nuts and new bulbs:



And here we go, clocks, switchgear and, after consulting the forum, new Yamaha grips, all fitted:



Now preparing to do battle with this lot!:

'80 RD400F, coming together slowly
'75 RD350B, my retirement project at this rate!
'01 ZRX1200R
'01 GSX-R1000 K1

Offline Bofski25

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Re: GR400's 400. First timer restoration
« Reply #101 on: June 02, 2019, 06:42:29 PM »
Keep up the good work