right where do i start.....
gear needed, 1x bandit back wheel, 1x gs500, 2xwheel bearings(depending on weather you use the gs axle or the bandit one) 1x caliper bracket (either gs or bandit bracket) 1x caliper(bandit if you want to mount it to the underside of the swing arm or gs if you want to mount it to the top) 1x gs cush drive complete with bearing(bearing will need to be changed to bandit one if you use bandit axle) 1x disc (you cant use the gs disc im afraid) 1xaxle either gs or bandit(if you use the bandit you will also have to get the bandit wheel adjusters)

1 tools, spanners for taking the wheel off and brake arm ect, hacksaw, screwdrivers (a sparkys bestfriend) grinder (mu hu hahaha new to my armoury of bodging gear $20 from b&q)
pencil,

now that we have tools(all beit very few) its time for the bodging to begin :mr green:
step 2, put bike on its center stand, oh if like me you dont have one improvise

step 3, remove the back wheel, brake caliper, chain guard, foot rests,
step 4, get the gs cush drive off the crappy gs wheel.

step 5, remove the bearings from the bandit wheel, (if you are using the gs axle) get some gs bearings from weremoto and chuck them in(the outside diameter is exactly the same and also the width is the same as oneanother its just the inner diameter thats different the bandit is 20mm gs is 17mm)
so now you have a bandit wheel thats ready to go on.

your next mission is the brake caliper bracket, you have a few choices here 1 use the gs braket and have only half the caliper bracket, 2 use the bandit braket with the gs caliper and have 3/4 of the pad rubbing the disc or 3 use the bandit bracket and the bandit caliper and have all the pad touching the disc( if you choose this option it means that you have to get a tab welded on the bottom as its set up to be mounted on the bottom of the swing arm)

the one on the left is the cut down bandit braket, center is the standard bandit bracket and right is the gs bracket

if you have decided to use the bandit bracket and the gs axle you have to get a bush made(from 20o.s diameter to 17 i.s. diameter, i got a peice of brass 20mm pipe from an engineer and sanded the inside slightly and it worked a treat)

now that you have your bracket and caliper the next issue of the day is the torque arm,

bandit at the top and gs at the bottom. the bandit arm will just give you clearance( and i mean just, no really just)

so i'd get that bend a little just for prosperitys sake if nothing else, at the moment i have just moved over the gs arm untill i pick the bent one up in the morning

right well now that thats all done its time to mount your fat new wheel.

and compared to the skinny gs one

and the side

right kids im done, i did some measuring and it looks like im bang on center, give or take half a mm, i don't know how that happened but im not complaining
:mr green:

oh yeah you can use a gsxr caliper (exactly the same as the bandit) and also the gsxr disc is the same as well.

I wanted to add dgyver's and my twist to this.The Bandit inner wheel spacer's inside diameter is to big to safely work and the GS spacer is to short.When replacing the Bandit wheel bearings,with GS bearings, we made a spacer from 2 GS inner spacers.The bandit spacer is 97mm long and the GS spacer is 88mm long.Dgyver cut a GS spacer down and weld it to a full length GS spacer.Then he faced the cut end down,with a lathe, to 97mm to make sure it was square and true.Install the bearing on the sprocket side first flipped the wheel over,dropped the spacer in,and installed the other bearing.Now that the wheel is done, we moved onto mock up in the swing arm.We found that no 2 swing arms have the same inside demensions between the arms.When we mocked everything up we knew the GS brake caliper hanger was to long.There's no easy way to use the bandit hangar.The axle hole is to large and you have to use the Bandit caliper.So we found that a 98+ Katana 600/750 brake caliper hangar positions the caliper right on the bandit wheel's brake disc.When we attempted to install everything it was to wide and the caliper and bracket set out to far,rubbing the disc.We took the spacer out that goes between the caliper bracket and wheel bearing.The spacer needed to be cut down to center the caliper and allow everything to fit inside the swing arm.Dgyver turned down the spacer until the caliper centered up on the brake disc.The tolerances are very loose for this and final length should be between 22.5 and 23mm.The cast caliper bracket accounts for the large tolerances.After the spacer was machined everything dropped right in.I had to open up the swing arm a little with a bar clamp.

To recap

We used GS wheel bearings,2 inner GS wheel spacers.1 cut down and welded to the other, to make a 97mm spacer.Ends of the spacer must be square.We used a lathe.Any way of cutting the spacer and keep it square is ok.Remember to install the sprocket side bearing first,flip the wheel,drop in the spacer and install the other bearing.Don't worry if the spacer is off center.You can use the axle bolt or long screw driver to center it.

I wanna add that the center spacer is hardened steel and will not cut with a hack saw.We used an angle grinder and cut of wheel.Also,the spacer needs to be tack welded and ground down.It is a captured spacer and if it comes apart inside the wheel the bearing has to be removed to re align them.So have them tacked in at least 3 places.

Fitting in the swing arm,we used a 98+ Katana 600/750 brake caliper hanger.We had to center the caliper over the brake disc.To do this, dgyver cut down the spacer between the caliper bracket and wheel bearing to 22.5-23mm.Dgyver used a lathe to cut it down,but any way that will keep the spacer square is OK.We removed the sheet metal guard off the end of the spacer to machine it.We reinstalled it after everything was mocked up.

We were in a hurry so we didn't get to take any pics of the inner wheel spacer.Here's some I took after I got back home with the parts.


The silver spacer on the left has been cut down to 22.5mm


Another view.


Here are the caliper brackets.The black 1 on the left is a GS and the silver 1 on the right is 98+ Katana 600/750.All GS brackets are the same.


Katana bracket in front of GS bracket.Axle bolt is to line them up.There is just enough length in the GS that the Bandit rotor only seats half way into the caliper.

kudos and all guys but i hope someone puts this on the wiki   or in the faq part of the forum before this get lost and burried among the hundreds of other threads...

it is on the wiki , pity i bought a B6 wheel and then learned about the spacer problem .... i got a almost new 150 tire off it tho , and i payed 20 quid for a wheel , so it was all gd

Quote from: Jay_wolf on May 19, 2008, 09:54:30 AM
it is on the wiki , pity i bought a B6 wheel and then learned about the spacer problem .... i got a almost new 150 tire off it tho , and i payed 20 quid for a wheel , so it was all gd

I never found anyone to make the inner wheel spacer.Machine shops refused because it was metric.Bike shops refused cause it was a liability issue.Then Dgyver and I got together and sorted it out the easiest way possible.I'm working on a small hobby lathe.I hope the other guy doesn't buy it before I get my $$$ there.

Can we get a pic of your chain clearance via tire.

it wasnt there last time i checked..although i do see it now.... maybe im just blind

Quote from: seamax on May 19, 2008, 11:56:36 AM
Can we get a pic of your chain clearance via tire.

As soon as I can get it out of my dark building.Still in the reassembly stage.My whole bike is tore down for mods and rust removal.The tires I will be running are 120-60-17 and 160-60-17 Shinko OO5 Advanced.Dgyver showed me a set of Michilien Sports that are identical to my 005's.He believes Shinko bought the molds from Michilien.The tires are identical except the logo.

160-60-17 rear is wider than expected. I made a 3.5mm spacer to fit between the inner sprocket carrier spacer and the wheel bearing.Problem solved but the chain still runs close to the tire.It may be 1/8th of an inch.

Quote from: ben2go on June 10, 2008, 10:43:44 PM
160-60-17 rear is wider than expected. I made a 3.5mm spacer to fit between the inner sprocket carrier spacer and the wheel bearing.Problem solved but the chain still runs close to the tire.It may be 1/8th of an inch.

Same with my 160, the chain is very close even after shimming it out as far as possible. My next tire will be a narrower 160 or a 150.

Quote from: bucks1605 on June 11, 2008, 06:59:33 AM

Quote from: ben2go on June 10, 2008, 10:43:44 PM
160-60-17 rear is wider than expected. I made a 3.5mm spacer to fit between the inner sprocket carrier spacer and the wheel bearing.Problem solved but the chain still runs close to the tire.It may be 1/8th of an inch.

Same with my 160, the chain is very close even after shimming it out as far as possible. My next tire will be a narrower 160 or a 150.

Sorry to hear that bucks.Hopefully my next wheel tire combo will be a TL 6.25 rear wheel with a Michellin pilot 200-55-17 in an 89 GSXR swing arm. 

Quote from: ben2go on June 11, 2008, 09:42:12 AM

Quote from: bucks1605 on June 11, 2008, 06:59:33 AM

Quote from: ben2go on June 10, 2008, 10:43:44 PM
160-60-17 rear is wider than expected. I made a 3.5mm spacer to fit between the inner sprocket carrier spacer and the wheel bearing.Problem solved but the chain still runs close to the tire.It may be 1/8th of an inch.

Same with my 160, the chain is very close even after shimming it out as far as possible. My next tire will be a narrower 160 or a 150.

Sorry to hear that bucks.Hopefully my next wheel tire combo will be a TL 6.25 rear wheel with a Michellin pilot 200-55-17 in an 89 GSXR swing arm. 

Damn!!! 

I am bumping this thread because a few people has PM'd me about installing a Bandit 600 rear wheel.Please take notice that my addition to this thread is only for the wheel that has swept spokes like the GS wheel.The straight spoke won't work from my experience.The sprocket carrier is different.I run Shinko 005 Advance tires 120-60-17 front and 160-60-17 rear.









Before any one asked about my mods see this thread please. http://gstwins.com/gsboard/index.php?topic=42478.0