My GK76a first project on a budget

[Tonyj]

Hi lads a few weeks ago I bought a Gsxr 400 76Gka on a 90 G reg. Eventually managed to get her home from work to my mothers garage and had a few hours so I decided to strip what I could and see whats what. Ill try and keep this goin when I can but I hope you can all show some patience with me as this is all new to me, I enjoy reading your posts and watching your builds take place- Ive got massive amounts of respect for the work you lads have done - and hope that I too can create something to be proud of too.

Here are some pics of what I managed to get done this afternoon sorry theres a few pics and I welcome any advice and constructive comments

When i picked it up


First removing the glued together screen where someone had overtightened screws


Next removing plastics to see whats underneath- no surprises really
These need some work

Front end okay has good Pirelli Diablo rubber, forks good and brakes good but no braided lines-yet

[Tonyj]

Some more progress:

Unfortunately I found the exhaust is blowing underneath the 4-1 join, the bugger was fine when I brought it home now wtf

Homemade stubby oem suzuki at some point now butchered. and this is a M- max unit is this standard equipment ? i seem to recall seeing this in a post here.

Good Pirelli Diablo rubber at the back and a custom hugger.

[Tonyj]

Like i said im a beginner but what I lack experience I make up in enthusiasm and although i dont have a lot of time or money ( Im married lol) I hope i can end up with a finished bike like some of your projects on here.
cheers for readin my post lads and lasses

[Marsbar]

Looks good, no the M-box aint standard. Whats your plans? just a tidy. And lol at that stubbyed can . im stubbying my yoshi can but should look alot better then that. standard can is to quiet.

[Tonyj]

Hi Marsbar, initially looking to tidy but also interested in swapping bits for more trick bits and updating wherever possible and funds allowing.

[Tonyj]

Update- Attempted to remove rear subframe on sunday but subframe bolts seized solid -actually snapped a halfords professional tool first use on the fookin thing. Then removal of exhaust headers, both outside collars removed easy first inside snapped bolt, so purchased set of easy outs from ebay waiting for arrival.

Been advised by tech at work just to drill and retap as if easy out snaps theres no chance of drilling through- any advice on this anyone?? Its really awkward space to work around header into bolt space..

Most screws and bolts siezed slowing progress atmo really frustrating as wanna get bits painted together , so taking bike back to work get windy gun onto em hopefully shock em out plus heat will sort

feels like a wasted day after all this

On the plus side my gsxr600 k8 shock on way

[dunkenb]

I had a snapped bolt on my front sprockett which came straight out with a left handed drill bit. And cheaper than a set of easy outs.

[Tonyj]

Hi Dunkenb, i got a kit from fleabay well two kits for 6 quid lol - silverline damaged screw remover set and screw extractor set which i think im gonna need both cos every other bleedin fastener is either rounded, or seized.
Think the extractor set is like a left handed drill bit, bit worried bout using em for the downpipes tho in case they snap and then am fooked...

Oh gsxr600 k7 shock in yellow arrived today so hopin to get that fitted this weekend- if I can get the bolts undone lol

[Tonyj]

Hello again, no pics this update- got loads but cant upload for some reason.

Been busy at work for a while but managed to make progress, heres a few tasks I managed to get done

why is it that when you approach a task on a 20yr old bike you plan it out and think itll take this long but it never does? Im learning quickly about that.. thinkin bout gettin shares in WD40 lol
anyway heres what I managed to get done in a few hrs here and there at work..

whole back end stripped
subframe rubbed down rust treated prepped for paint,
swingarm off being cleaned up as we speak needa hugger bracket welded back on
started cleaning up the shock linkage and ended up on the wire wheel at work so thats polished up now too.
Oil drained from the engine so I can get the casing rubbed down for paint.
chain off and soaking in oil as a bit dry and neglected- should be good i hope, we'll see.
wiring cables etc labelled cleaned up plenty of pics taken to remind me of location for refitting
coolant drained rads off to access downpipes

Noticed theres about 8 large holes at back of airbox must have been drilled by previous owner, is this common??

Had a small shopping spree so will get some work done now Items bought-

Silencer thanks fluffyv as my stubby a bit rough where welded
Stubby Levers Black and Yellow/ Gold (for rgv250 but same fitment)
Gsxr600 K7 shock and spring Yellow spring- perfect
Fork Oil seals
Fork Oil
Tapered head Bearing Kit
motrax grips black with yellow detail
Hiflo Oil filter
5 Litres 10/40 oil
various tools- various larger sockets, screw extractor sets etc etc
Getting replacement rear hugger thanks fluffyv as mine been cut to a point( why the hell would anyone i dunno??)

edit
new shopping list
sintered pads
wheel bearings
just for now, sure it will grow tho


So a few jobs to be getting on with for now, Ill add pics soon..
cheers for lookin

[Tonyj]

Update, works been crazy lately 13-14 hr shifts over 6 days so not progressin as quickly as i had hoped. Anyway heres a brief update...

swingarm off gettin the hugger bracket on rhs welded back on cos I snapped the f-in thing off so soon as thats back its getting painted. While thats off located the 07 600 gsxr shock spring bolted at top while I polished the linkage, linkage polished nicely so went to fit lower bolt (after bolts cleaned up on wire wheel and greased up of course) and the hole didnt line up so had to grind away my newly polished linkage-gutted but now it clears.

Pics to follow

Hopin to make more progress at weekend.. frustrated at lack of progress atmo