Project: GB400 Cafe Racer re-rebuild [Archive]

durp

7th February 2012, 10:34

So after i got my hands on this, i had been building it up a little bit and was pretty content with how it was looking. But then the motor blew on saturday after the vintage bike races in pukekohe (only watching, wasn't racing). So I'm starting a full rebuild project.

Trying to get my hands on an XR600 motor, so if you know anybody...

Heres how it was looking as of saturday:

<img src="http://f.cl.ly/items/3A032Y2J3z2Z0h271I2i/GB4001.jpg">

<img src="http://f.cl.ly/items/2m2J0y1N3h1t400L0N2P/GB4002.jpg">

durp

7th February 2012, 10:41

So sunday i decided to get started stripping it apart. Gotten it pretty much down to nothing now. Pulled motor, removed just about everything.

<img src="http://f.cl.ly/items/0Q1P0K3F3H060b2z073e/1.jpg">

<img src="http://f.cl.ly/items/2V0v0Q2W423j41101437/2.jpg">

<img src="http://f.cl.ly/items/2d412N270b1F1a2v2C3J/3.jpg">

<img src="http://f.cl.ly/items/0G2H3U2w3U2x0n2C003R/4.jpg">

<img src="http://f.cl.ly/items/2Q2w2X2C2X1H3Z173U07/5.jpg">

durp

7th February 2012, 10:42

Began grinding off mounts that wont be needed now from the frame and smoothing them out.

<img src="http://f.cl.ly/items/1V15252U2O3i1c2e0E3r/6.jpg">

dogsnbikes

7th February 2012, 11:59

Bugger about your motor

Try contacting Eelracing on here,I brought a GB500 motor of him about a year ago and he had a XR650 motor sitting there..... wether or not he still has it,is anyone guess but worth a try,

How much damage too the GB motor and if your planning on wreaking it I am looking for some parts well the cam chain adjuster:msn-wink:

durp

7th February 2012, 12:04

Cheers for that. Sent him a message, heres to hoping.

I'll keep ya in mind if i dont end up finding a motor.

Sable

7th February 2012, 15:39

Instagram is for soy latte drinking limp-wrists. Just sayin'.

durp

7th February 2012, 15:40

hahahaha, yeah about that. somehow deleted all the originals from the phone. only ones left were up on instagram.

durp

8th February 2012, 10:20

Smoothed off some brackets from the frame that wont be needed any more.

Ready to send off for sandblast and powder coating.

<img src="http://f.cl.ly/items/061x2N461i1k3F3m2p0o/frame1.jpg">

<img src="http://f.cl.ly/items/3K0K39440k1e1a0u2C1g/frame2.jpg">

nzspokes

8th February 2012, 10:26

Would it not be better to wait to see whick motor your going to use before painting the frame?

durp

8th February 2012, 10:27

nah :banana: Just getting it black again. Just needs refreshed.

Im not going to go with a motor that wont bolt right in.

nzspokes

8th February 2012, 10:55

So what blew on the motor? You cant just fix it? they are simple motors.

ICE180

8th February 2012, 11:00

Look for a NX650 domnator motor they bolt in and the gear box is round the right way the XR motor will have the gears upside down

also if you are doing the XR motor avoid the twin carb models (85-87) I think hard to get running really well

durp

8th February 2012, 11:03

Thanks for that. Keeping my eyes open.

I haven't had a chance to crack the motor open yet. But from the sounds of it, thrown a rod or something. The cams turning but nothing happens.

eelracing

8th February 2012, 14:54

Cheers for that. Sent him a message, heres to hoping.

I'll keep ya in mind if i dont end up finding a motor.

PM replied to but unfortunately not good news.

Love the look of your cafe racer tho hopefully back on the road soon.

durp

8th February 2012, 14:55

Yup just saw that. Thanks for the reply. As long as i can get a motor in there, shouldnt be too long before back on the road. maybe a few weeks

Hareaway

9th February 2012, 06:12

Hi , i have just started breaking down a GB 400 as well . Have just bought it and was going to ride it for a bit but started making bad cam chain noise so now have it in bits .

I havent done a cam before and guess i will need a new chain tensioner , as i live in the sticks and have to order parts is there anything else (spring, guide etc) i should order .

Sorry for jacking your thread Durp

durp

10th February 2012, 16:04

Looks like Ill have found some motor options finally. Pretty good prices as well. Glad for that.

Currently working on the loom. Got a few electrical bugs worked out last night, and going to begin rewiring and simplying it tonight. I'll share pics of course later.

While at work today, I was starting some designs for the bits and pieces I'm going to build. Started with the new foot-peg frames. Heres the direction I'm taking it.

<img src="http://f.cl.ly/items/1T0n191P203p3P353Z3Q/foot-peg-frames.jpg">

durp

17th February 2012, 14:57

Black wheels are really sexy. Glad I just did em.

<img src="http://www.noahyamen.com/uploads/rebuild-photos/Wheel-1.jpg">

<img src="http://www.noahyamen.com/uploads/rebuild-photos/Wheel-2.jpg">

durp

20th February 2012, 11:07

Putting some stuff back together
<img src="http://www.noahyamen.com/uploads/rebuild-photos/Wheel-3.jpg">

More assembly, black fork sliders now
<img src="http://www.noahyamen.com/uploads/rebuild-photos/wheel-forks.jpg">

Semi-rolling frame, will making it easier to run the new wiring
<img src="http://www.noahyamen.com/uploads/rebuild-photos/wheels-on.jpg">

Going through and simplifying the loom, still have some more to do, but will have to wait till i start wiring on the frame to get lengths right.
<img src="http://www.noahyamen.com/uploads/rebuild-photos/wiring-1.jpg">

The miles of awful tape that someone put on before.
<img src="http://www.noahyamen.com/uploads/rebuild-photos/wiring-2.jpg">

AllanC

21st February 2012, 05:33

Looking good!

durp

21st February 2012, 13:16

Some more of the battery mount assembly
<img src="http://www.noahyamen.com/uploads/rebuild-photos/battery-mount.jpg">

durp

24th February 2012, 09:21

big thanks to NZMikey for hookin me up with the tow.

<img src="http://f.cl.ly/items/021n161f1N2b3f0d0t2Y/2bikes.jpg">

Got 2 GB's now. Got the new one up and running last night. Owner hasnt been able to find the key yet. So swapped ignitions over. Gotta friend comin to pick up the ignition from me today, and will make up a new key for me in between jobs. Score. Then i can get the tank and seat off without destroying parts.

nzspokes

24th February 2012, 09:33

If you want to sell a few parts off the parts bike i know somebody that could be intrested.

durp

24th February 2012, 09:34

Ill be sure to keep you in mind when i get to that point. Right now, its going to be a daily rider till im ready to move the motor over.

Canis G.

24th February 2012, 18:30

Did you find out what broke in your old motor?

durp

25th February 2012, 01:07

Workin it out in the spare time. I was thinking maybe it was just the timing chain. But it seems fine. My guess at this pint is maybe thrown a rod or seized piston.

ICE180

26th February 2012, 16:07

like the battery mount idea luck its a gel batt no acid huh

durp

2nd March 2012, 17:20

Thanks man.

Pic I just took of the new daily runner. But gives hints to some of the new things to come on the project GB.

<img src="http://f.cl.ly/items/243a3l3b2B19170H3744/Most-Recent-GB400.jpg">

Sable

3rd March 2012, 09:50

Nice, it has lost a bit of the retro-ness though.

durp

3rd March 2012, 09:53

Thanks. How so tho? Mind you, this is just the spares bike.

ICE180

15th March 2012, 15:19

hows it comming along
I have a new project to but need a donor engine we might be able to help each other out with doner parts