Bandit Refurb
Posted: 04 Apr 2015, 22:57
Got myself an 03 naked Bandit back in November to use a a commuter and winter hack. Now seeing as the weather has warmed and the salt has gone I thought it was time to get the Tuono out of hibernation and start on 'Project Bandit Refurb'. She's a good solid machine but suffering from years of neglect and poor maintenance.
The list of to do's :-
Full front and rear brake caliper rebuild.
Braided brake lines.
Re-chrome fork stanchions.
New fork seals.
Fix 2 snapped header bolts.
Address issue with oil cooler hoses (became apparent after fitting new oil cooler).
New chain and sprockets
So the front cailpers got stripped and the first major problem was seized pad retaining pins. Couldn't get them out so was forced to make a caliper modification by drilling a hole through the caliper body directly behind the blind hole for the retaining pins and knock them out with a drift. After they were removed the calipers got stripped,cleaned and overhauled, the pistons removed and cleaned and polished, new seals and pads and a set of stainless pad pins fitted. They are now rokckin' and ready to go.
Next up the rear caliper and this was worse than the front. Again a seized pad pin, so went down the same route as for the front. When it came to removing the pistons the rear unit has to be split by removing 2 bolts holding the caliper together. 8mm allen head bolt completely rounded out. Hammered home a spine drive but it just would not budge and started to spin, so out with the dremel, i cut 2 flat sides off the head of the bolt and put it in the bench vice, then using a big pair of stilson grips, slowly started to get the fecker undone, 12 years of grime, cack, salt and corrosion held that sucker tight but i got it out. As before cleaned and polished pistons, new pads, O rings and a fresh shiny pair of stainless bolts to hold the caliper back together and they too are ready to rock.
After
The list of to do's :-
Full front and rear brake caliper rebuild.
Braided brake lines.
Re-chrome fork stanchions.
New fork seals.
Fix 2 snapped header bolts.
Address issue with oil cooler hoses (became apparent after fitting new oil cooler).
New chain and sprockets
So the front cailpers got stripped and the first major problem was seized pad retaining pins. Couldn't get them out so was forced to make a caliper modification by drilling a hole through the caliper body directly behind the blind hole for the retaining pins and knock them out with a drift. After they were removed the calipers got stripped,cleaned and overhauled, the pistons removed and cleaned and polished, new seals and pads and a set of stainless pad pins fitted. They are now rokckin' and ready to go.
Next up the rear caliper and this was worse than the front. Again a seized pad pin, so went down the same route as for the front. When it came to removing the pistons the rear unit has to be split by removing 2 bolts holding the caliper together. 8mm allen head bolt completely rounded out. Hammered home a spine drive but it just would not budge and started to spin, so out with the dremel, i cut 2 flat sides off the head of the bolt and put it in the bench vice, then using a big pair of stilson grips, slowly started to get the fecker undone, 12 years of grime, cack, salt and corrosion held that sucker tight but i got it out. As before cleaned and polished pistons, new pads, O rings and a fresh shiny pair of stainless bolts to hold the caliper back together and they too are ready to rock.
After