Author Topic: GR400's 400. First timer restoration  (Read 25669 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

Online 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, restored
'75 RD350B. Not touched for at least 20 years. Next up
'01 ZRX1200R
'01 GSX-R1000 K1

Online 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, restored
'75 RD350B. Not touched for at least 20 years. Next up
'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

Online 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, restored
'75 RD350B. Not touched for at least 20 years. Next up
'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

Online 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, restored
'75 RD350B. Not touched for at least 20 years. Next up
'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

Online GR400

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Re: GR400's 400. First timer restoration
« Reply #102 on: December 03, 2019, 06:32:45 PM »
Another update.  Still not finished, but making progress.  I'm feeling quite optimistic about 2020.  It'll be 40 years old next year so would be nice to get it to the Club Rally  :)

The last time I checked in here I was about to get stuck into connecting up the electrics, which I have done a bit, but got side-tracked along the way.

First electrics task was connecting up engine and CDI.  Last year Rex’s Speed Shop rewound my stator and fitted new wiring.  They told me the original connectors were no longer available so had fitted alternatives and gave me the other ends to fit to my main loom.  I wasn’t too happy about desecrating my NOS loom, but took a deep breath and got on with it.

So before:


And after:


Connected it all up,  loom into clips, and new flasher relay:


And electric plate on with new regulator.  It’s a snug fit behind there!


Next I thought I would get the engine timed up.  First purchase was a flywheel holding tool to get it torqued down, and then I did my research on here around dial gauges with feedback that many do not fit the 400 engine in frame.  I carried on looking for small gauges and came across the Buzzetti timing tool.  It’s like a micrometer with a probe underneath that screws into the plug hole, like a gauge but much more compact.  Venhill do one the same so I bought it.  If anyone is thinking about one, don’t do it!  The probe is too short and doesn’t reach the piston crown.  So I returned that and bought the smaller (and more expensive) of the two gauges that Yambits offer.  There was some dispute on here over whether that would fit the 400 engine in frame, but happily for me it did.  I did have to cut the probe down though.  The short one supplied is too short and the long one too long, but I got there in the end and timed to 2.0mm BTDC:


I fitted the indicator cancel unit while I could get at it and loosely attached the original coil.  I am still tempted to replace it with a new one, maybe Dyna if I’m feeling flush.


Then on to the oil pump.  This has been waiting in a box all lovely and refurbed for some time, so out it came with new gaskets and oil seals.


Kick start and oil pump seals fitted to engine case, new oil lines plumbed in (I know the clear carb lines are not strictly correct but I want to see the oil flowing through them), then fit the case with new olive drab screws.  I also fitted the kick start to check the mechanism working freely.


And finally, fit the pump and connect hoses and cable:


Then with hindsight a mistake with the order of things.  I filled the gearbox with oil to make sure it was oil tight before moving over to the other side of the engine to connect up the clutch……..and it was so heavy I could barely move the lever.  I checked cable routing, swapped the actuator, but it was no better.

So with lots of cursing I drained the gearbox, removed oil pump and pulled off the engine casing.  Could now see the pressure plate was barely moving.  When I assembled the engine I bought new clutch springs from Yambits which are listed as 10% stronger than OEM.  So I now bought and fitted a set of genuine springs from Fowlers, and lo and behold, nice smooth clutch action.  I don’t know if I got a rogue set from Yambits, but beware.  I put it all back together again and refilled with oil.  Still oil tight and I hope not to be opening it up again any time soon.

Rear brake master cylinder fitted, another lovely NSRnick job, along with reservoir and brake pedal, so all ready now to fill and bleed:


I got all the footpeg bits and bobs together:


And reunited them with their arms, the last thing from the powdercoating pile – Nice milestone!


I am not putting the right side footpeg on until I get the back brake bled and adjusted, but the left side could go on.  Pipe (work of art from Martin) and gearlever also fitted to make sure nothing touches.  All good and that can stay on now.


Number plate on, very nice job from Tippers, and it’s really starting to look like a motorbike!


Next get the brakes working, complete the electrics, and then I must be getting dangerously close to trying to start it!





















'80 RD400F, restored
'75 RD350B. Not touched for at least 20 years. Next up
'01 ZRX1200R
'01 GSX-R1000 K1

Offline Comms Guy

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Re: GR400's 400. First timer restoration
« Reply #103 on: December 04, 2019, 08:33:54 PM »
Well done Gaz. About time you gave us all an update. Get it done for Xmas as a present to yourself :D :D :D

Offline Kickstart

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Re: GR400's 400. First timer restoration
« Reply #104 on: December 04, 2019, 09:06:33 PM »
looking very tidy, can't wait to see it complete 8)
A/C HOOLIGAN