Zach Zodiac
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 1991 GSXR400R GK76A Head rebuild
I've already had so much help thanks to this forum - Big ups to GSXRacer.
I have photos of my project on my website if anybody would like to see a 1991 GSXR400R GK76A in pieces and what tips I've learnt doing some of the stuff myself (I am far from mechanically minded).
It's in a blog style, so if you want to start at the bottom and see how the project developed then ok, otherwise wait for the pics to load and follow the headings about particular aspects of the project you're interested in.
www.ingreenienz.com/projects/gsxr400r.htmhttp://www.ingreenienz.com/projects/gsxr400r.htm
Last edited by Zach Zodiac, 7/12/2007, 6:27
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7/12/2007, 5:54
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gsxr400racer
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Re: 1991 GSXR400R GK76A Head rebuild
no problem brother, that peice from the head looks like a brocken rocker arm but hey you have a spare now and usually when they break you mess up valves and a piston or two. Hope fully daz (stripes1976) will chim in as he is the 76 expert
cheers
Jay
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Supplier of the cheapest 442cc big bore piston kit for gsxr400 73,76, bandit 400, and other suzuki's. Plus carb rebuild kits for the above bikes
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8/12/2007, 14:45
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garynortheast
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Re: 1991 GSXR400R GK76A Head rebuild
Enjoying reading your blog and following progress on the bike there Zach. Good to read about other peoples' projects. Keep it up and don't forget to put a few pics up here once the bike is finished along with a first ride report.
--- Gary.
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8/12/2007, 16:43
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Zach Zodiac
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Re: 1991 GSXR400R GK76A Head rebuild
That's a plan Stan.
I just uploaded a video showing the pistons - they are fair rooted! I can't wait to get the ol' girl back on the road.
Sure enough about the rocker arm. I don't know how I didn't notice when the cams were still on, but the valves in the number one cylinder were barely attached! I don't know why I didn't hear the engine rattling!
Has anybody seen such damage to the pistons before? I suppose there's been worse.
Has anybody at these forums done their own paint job? I am keen to hear any tips. I will be preparing the faring over X-Mas.
Last edited by Zach Zodiac, 17/12/2007, 6:30
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17/12/2007, 6:27
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garynortheast
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Re: 1991 GSXR400R GK76A Head rebuild
Zach, you'll have to excuse me not watching the video as we only have a dialup connection here - can't get broadband in the village.
There's been a few people on the forum here in the past who've done their own paint jobs. Stripes is one (if you can catch the elusive beggar!).
--- Gary.
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17/12/2007, 20:51
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Zach Zodiac
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Re: 1991 GSXR400R GK76A Head rebuild
Yeah, I have to admit since I got broadband I've become addicted to YouTube. I will try to tack down Stripes.
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18/12/2007, 7:45
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gsxr400racer
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Re: 1991 GSXR400R GK76A Head rebuild
your supposed to pull the pistons in and out your looking for play in the rod big end thats connected to the crank
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Supplier of the cheapest 442cc big bore piston kit for gsxr400 73,76, bandit 400, and other suzuki's. Plus carb rebuild kits for the above bikes
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18/12/2007, 19:06
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gsxr400racer
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Re: 1991 GSXR400R GK76A Head rebuild
that piston is shagged as much as id like to sell you new big bore pistons i do have a ton of stock used in good shape pistons if you only need one and can get you new rings as well. But it all depends on your bores and how fast you like to go.
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Supplier of the cheapest 442cc big bore piston kit for gsxr400 73,76, bandit 400, and other suzuki's. Plus carb rebuild kits for the above bikes
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18/12/2007, 19:09
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gsxr400racer
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Re: 1991 GSXR400R GK76A Head rebuild
or your mechanic might mean to take the pistons off the rods by removing the clip and pushing the pin out then taking the rings off the piston stick them in the cylinder and see how much wiggle play there is
---
Supplier of the cheapest 442cc big bore piston kit for gsxr400 73,76, bandit 400, and other suzuki's. Plus carb rebuild kits for the above bikes
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19/12/2007, 6:18
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stripes1976
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Re: 1991 GSXR400R GK76A Head rebuild
hey i may be a little hard to track down but i have had good reason!!!
over xmas i have had 3 family members in and out of hospital then it ended with a funeral last week! 
If anyone needs me and i'm not about email me at molie2000@hotmail.com
keep up the good work zach!
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5/2/2008, 21:46
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