Suzuki Bandit 1200 Clutch Replacement / Barnett Clutch Kit

My 1999 Suzuki Bandit 1200 had clutch slip at full throttle in some gears and in this video I replace it for a Barnett unit. Overall the install was straightforward save for the spring washer retainer cup which I found a bit finicky on install.
I bought my kit from Revzilla and think I got the last one as they currently show out of stock: www.revzilla.c...
8/20/24 this bike is FOR SALE - check my latest video on the bike
Bandit 1200 Playlist: • Suzuki Bandit 1200
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#brickhousebuilds #bandit1200 #motorcycleclutch

[@James-dt7ky]

Nice to see the little "errors". Serves as a good learning lesson for me to watch out for.

[@BrickHouseBuilds]

We all do it lol

[@JustanOlGuy]

I appreciate the fact that you keep it real and show yer foibles,

[@BrickHouseBuilds]

@@JustanOlGuy I always do as we are all human 🙏

[@JustanOlGuy]

@@BrickHouseBuilds Indeed.

[@nickrider5220]

Love the oil cooled Suzuki motors, advanced air cooled with a bit of attitude 😎

[@BrickHouseBuilds]

🤘🤘

[@daveco1270]

First time I've seen a clutch with wave washers rather than springs.

[@BrickHouseBuilds]

First I have experienced one as well

[@jameshisself7375]

Common in Harleys, first I've seen in a Suzuki

[@BrickHouseBuilds]

@@jameshisself7375 dang I totally forgot that's how my Sportster was!

[@henryhawk978]

Enjoyed the HOW TO on the clutch. V-MAX is a thirsty machine...especially if you're constantly ringing its neck! Mine burns lots of gas! Enjoyed the video BJ and ENJOY AND RIDE SAFE OUT THERE!

[@Justk75]

Vfr 400s use these springs also

[@andrewashman3333]

My favourite channel - great presentation, no ego, informative and plenty of humour (and great bikes).

[@BrickHouseBuilds]

Glad you enjoyed 🙏

[@jessiec4128]

My first bike I had at 12 years old was a Honda XR-75. It came from one of my good friends who used that bike to race. Also his older brother also was in to Racing. My brother purchased it for me after the owner upgraded classes. And it was an Awesome bike. I was friends with twins who got Honda XR-80 bikes. But they were so slow compared to my bike. I did let them both ride my bike and I rode their bikes. It was a major difference . And the older twin by a few minutes wanted my bike really bike. And even trade, but I turned him down. My bike was in perfect shape. I often see new riders when trying to ride a motorcycle they always give way too much gas and they never let it go. Eventually they wreck. When I first rode my XR-75, Yes it took off but just a short distance. As I fine tuned myself to ride it. I really enjoy these videos!

[@mistermacgray]

It's the errors that show us what mistakes we can make as humans but also show tips and tricks to help us avoid mistakes and we learn from them.

[@BrickHouseBuilds]

🙏

[@AndyH-13]

I also use a ring spanner on an open end spanner to get some extra leverage when needed. Works a treat and saves skinning your knuckles.

[@stevenwarner7348]

So so so sweet to see the Bandit on the road. Thank you so much! New Hampshire. ♥

[@joeblow229]

This bike brings back a lot of memories! I had one that I stripped the fairing and plastics off of, added pod filters, etc.. It was a ton of fun making it into a skeletonized street-fighter bike.

[@BrickHouseBuilds]

🤘🤘

[@bordone]

Bought a red bandit off a college student who was moving out of state. It was in ruff shape from the novice rider abusing the poor bandit but I got it for $900! It barely ran and needed alot of work but since I turn my own wrenches, I got her going for cheap. Greatest bike I ever had for the price.

[@flexjay87]

I like that little video edit of flipping the oil wrench around after first starting it on the wrong way :) The bandit is a pretty cool old school bike. The V-max seems to be nothing but trouble, but it shows your perseverance on owing it !

[@BrickHouseBuilds]

Well any bike is going to give trouble after sitting for so long. This is just part of the deal. Running out of fuel was our fault

[@Justk75]

Brilliant how to .fantastic content and format as always 🏴󠁧󠁢󠁳󠁣󠁴󠁿

[@BrickHouseBuilds]

Thank ya!

[@getwhtugiv]

Nice Clutch rebuild. We all learned a lot from this video.

[@BrickHouseBuilds]

🤘🤘

[@spontaneouscombustion_alert]

This video is as encouraging to me as the ones where everything goes fine. it makes me feel better! And I learn. I was watching one of your old carburettor disassembly videos today as I finally after literally a whole month (or more) managed to get the carbs out of the bike. First for me. I was watching the video of your sv 650... where you had all the seized scews... as do i. (still unresolved), I had disgusting petrol varnish too, which after a bout of futile wrestling with seized screws, I for some reason decided to put the carbs in the fridge, and off I went for a couple of hours to pick up the car from the mechanic (a real one).. I got back and opened the fridge, and my god. Not only were (and are) the carbs a different colour, the stench of varnished petrol in the fridge and all over the food is incredible! Wasn't even worth it, didn't fix all my srew issues, but sure screwed with my fridge vibe! Nice video BJ, I like the bandit!

[@BrickHouseBuilds]

Thanks for watching! Sorry about the early sv650 videos lol. They were terrible by today's standards

[@spontaneouscombustion_alert]

@@BrickHouseBuilds Not terrible, and very useful1

[@JoshA86]

Sweet video and actually good timing. My 2000 Bandit is needing a clutch this winter and was pricing out the stuff i need. I was gonna go with OEM but it is costly. Whichever i choose this has been a great informational video. Keep up the good work 👍

[@BrickHouseBuilds]

I definitely recommend this kit as it just had everything and is an upgrade for sure

[@johna6968]

Nice to see a yank not ruining a standard bike. That full rear mudguard is class 👌

[@BrickHouseBuilds]

Maybe don't watch a single other video on this channel as no fenders are safe 😅

[@mr1bienvenu1]

I love that Bandit, I had one just like it many years ago 😍

[@BrickHouseBuilds]

Awesome bikes for sure

[@perustc9158]

Just remembered that the '80's Honda Shadow has a similar setup. The Honda has the rotator pinned in a weird config. That particular unit ('86 I think) is prone to Hydraulic lock and is a pain to diag and repair. The son of a friend of mine still has the boat anchor sitting in his barn with enough crap on it to carve barn animals in it!

[@ThePahan007]

love the gv75a´s

[@ComandanteJ]

First clutch I replaced was on a Bandit 650, but that one has the regular 5 coiled springs. A friend is thinking about getting a 1200, so this is good reference!

[@jeangaelcognat4988]

Merci pour le partage et le montage de cette vidéo instructive

[@BrickHouseBuilds]

Glad you enjoyed

[@Mariano.Bernacki]

Something for you to research. Maybe it saves you time in the future. Pre-soaking clutch disks in oil is a remnant of the time when actual natural cork was used. Modern materials do not require soaking. Lightly applying a coat of oil with your finger as you are installing them is more than enough to prevent sticking in initial operation.

[@BrickHouseBuilds]

I plan to continue soaking. There is no downside

[@peteraitken6494]

Lovely bike the bandit and sounds real nice good job on the clutch,I thought you had edited out putting the filter on then you said damn forgot to change it hahaha love it keeping it real BJ your an honest man we all make mistakes but it’s so frustrating right ,lol anyways good to see the bandit fixed and the v max 2great bikes take care guys and have a good week 🏁🏁❤️👍🏍️🏍️🏍️🔧🔧

[@BrickHouseBuilds]

You know I always keep my goofs in these lol. Glad you enjoyed

[@peteraitken6494]

@@BrickHouseBuilds great video mate always enjoy 👌👍👍

[@Rasputins_grandson]

What a sick bike 😮

[@BrickHouseBuilds]

It's definitely the best version I could find

[@jameshisself7375]

Very interesting clutch design. Seems like it might be easier to build the plate stack with the basket and hub in situ. Beautiful result.

[@BrickHouseBuilds]

I am torn on the process. It seems it was meant to be assembled out of the bike and installed as a unit

[@paulnunn1039]

Did mine whilst still fitted in the main basket, had heard too many horror stories of people breaking the teeth on the back trying to realign. That can be costly.

[@cantosoares]

Duas motos excelentes... parabéns.

[@BrickHouseBuilds]

🙏🙏

[@AndyXL750]

You guys make a great double act 😂 Pushing the P-Max was sketchy AF...well played 👏👏👏🤣

[@BrickHouseBuilds]

Definitely sketch!

[@mistermacgray]

@andyplummer7270 I've seen pictures of it with two guys pushing on each peg but never a video of one pushing on the shock lol. It got the job done.

[@TheYorkie1954]

glad you mentioned the JIS driver you see many chaps bashing stuff around with Phillips drivers and butchering stuff

[@BrickHouseBuilds]

@TheYorkie1954 the most important tool in this shop

[@TheYorkie1954]

@@BrickHouseBuilds have a set in my shop even though I mainly have Brit iron, but you get the pdd Jap job in

[@jimclarke1108]

Another great bike to your personnel collection🛵

[@BrickHouseBuilds]

🙏🙏

[@RickRose]

I recently sold my 93 GSX 1100G. I think they have a lot of the same DNA. Mine was fun but top-heavy.

[@BrickHouseBuilds]

Definitely siblings so to speak

[@jameshisself7375]

Suweet! Sounds like just the right time to start that XR69 conversion that this baby is BEGGING for! Please man, it is so boring it is crying on the inside hoping for some redemption.

[@BrickHouseBuilds]

That would be sick looking for sure

[@trader4239]

Thumbs up for your skills

[@BrickHouseBuilds]

🤘🤘

[@lovetoflylovetofly3843]

2 sweet bikes!

[@BrickHouseBuilds]

Definitely 🤘

[@williamalley4976]

The Barnett Clutch is a good choice and will last You for a long time even if You put it to redline a few times, I know I did the same clutch in My CB750 Nighthawk and I race it in the Vintage races and No it is not a Stock Motor. I put 2 OEM clutches in with bad results they didn't last. Good luck and have Fun!

[@BrickHouseBuilds]

Yeah im confident in it for sure

[@stephenhepburn6374]

2 different steel plates as well on 5th and 6th in stack they are 2mm ,others 1.6mm

[@S2NAZ]

You make me miss my 1200 Bandit 😢 This was a great raw video and I love the un-edited mistakes👍🏻 I see your using your left hand as a torque wrench 😊 looking forward to the next one BJ. How’s the 924 coming btw?

[@BrickHouseBuilds]

@S2NAZ I always show my goofs lol. No time to work on the 924 unfortunately.

[@keithagn]

"I forgot to change the filter" DOH!! Best Regards from Canada 🇨🇦 😂

[@BrickHouseBuilds]

🤘🤘

[@andersaxelsson2196]

Nice one

[@johnsalvi9073]

You’re having terrible fun! That Suzuki is a great Sport Touring Bike.

[@BrickHouseBuilds]

🤘🤘

[@zobbyzockbrecht2469]

Regarding the oil filter: It is very sympathetic to show faults.

[@BrickHouseBuilds]

Happens to ALL of us 🤘

[@meredithsolutions1934]

mk1 B12 is a great bike

[@johnoconnor9331]

like the idea with aluminum how is the p max coming

[@BrickHouseBuilds]

The foil is a must have for a shop. P max is making progress. Sourcing parts now

[@councilquirks6601]

NICE VIDEO.....B-T-W.....I LIKE THE DANGEROUS "PUSHING" WITH THE FOOT ON THE SIDE OF THE ROADWAY.....SOMETIMES YOU HAVE TO JUST GET IT DONE THE BEST WAY THAT YOU CAN.....

[@BrickHouseBuilds]

Glad you enjoyed!

[@jonunya3128]

nice one. I actually think I could do that after watching..

[@BrickHouseBuilds]

Glad it was clear

[@perustc9158]

Like a "Glazed" donut!

[@BrickHouseBuilds]

🤣

[@jackbeanstock7710]

hey buddy, we are all human, we forget order of operations sometimes :) happens to us all

[@BrickHouseBuilds]

🤘🤘

[@michaelweilmuenster5754]

I think most of wanted to see a drag race between the Vmax and the Bandit.

[@BrickHouseBuilds]

@@michaelweilmuenster5754 It may happen. Vmax isn't ready yet

[@agee8322]

We all have days like that :-) .........

[@BrickHouseBuilds]

Definitely

[@MurraydeLues]

Put the oops down to stage fright, first time on camera or couldn't be bothered reshooting them. 😁 The Bandit scoots along quite nicely.

[@BrickHouseBuilds]

Well 4 years of filming my work it definitely wasn't stage fright but just an off day.

[@suzukibandit-t6n]

Hello. Did you notice that there are 2 steel plates of different thicknesses. They are 4-5 plates and they are thicker

[@yveslegrand9826]

😂 I did struggle a bit too on my first attempt...the easiest way to fit it is to put in 5th and rotate the wheel while pushing the disk stack. I am a bit concerned you did not mention the fact the 2 rings are not identical, the disk are not either (some are thicker!) and it's a ring missing under the diaphragm springs which are not "wave-washers"... My experience with Barnett's springs is that they make the clutch lever way too hard, but the clutch isn't slipping anymore though...

[@BrickHouseBuilds]

You're the expert 😉

[@cainbeeping8480]

👍

[@Thumpermad]

Another great Video thanks for sharing 👍 quick question ❓ I have a 2015 GSXR750 the clutch take up has never been very exciting to say the least. Probably the worst take up or engagement of any clutch I've ever had probably due to the concave washer spring system similar to the Bandit. The clutch is either on or off there's no real slipping action like you would I would imagine a Sport bike clutch to behave is there any fix for these type of clutch ? I've heard of swapping the clutch out for a spring design but don't really know what's suitable for the swap out 🤔 the bike has a 38K KMs on the clock and the clutch has always been pretty ordinary in my experience any help or advice would be great 😃 cheers mate Happy Trails 😊

[@BrickHouseBuilds]

Hmm, I can't say I have had that same experience. This has a great feel with plenty of modulation as you can see with the riding clips.

[@Thumpermad]

@@BrickHouseBuilds yeah mate maybe it's a slightly different setup I bought the bike 2nd hand it was immaculate condition but the guy didn't share much of the bikes history I'll pull it apart and have a look I've been thinking about selling it lately but I can't bring myself to do it as the market is Crap in Australia 💩 and the bike is still in amazing condition and goes hard if you happen to talk to someone who knows a fix that would be awesome man otherwise stay safe. Regards Tony in Sydney Australia

[@blondiejoe]

Damn, you know you love the bike when you employ the tinfoil drip curtain technique.

[@BrickHouseBuilds]

Always!

[@Scooterdude01]

Omg I once tried pushing my Honda helix , thought i was gonna die. Tapped the starter and she started right up. (After I got home)

[@BrickHouseBuilds]

We couldn't have ran out of gas at a better spot though with there being a lot of downhill. Still almost ended me lol

[@S2NAZ]

I’m really shocked you’re selling the bandit. That really is a very beautiful bike. Is it on a for sale site or are you selling it locally? 💔

[@BrickHouseBuilds]

@@S2NAZ I'm editing a video to go up tomorrow.

[@scottcates]

She scoots👍

[@BrickHouseBuilds]

For sure 🤘

[@diggy-d8w]

When there's nothing left to do But doing it....... Dive on in or procrastinate again? Not, I would but I own no tools anymore and I do still like seeing someone jump into a job, No Fear. Soaking the plates = smart. IDKnow all the reasons but if you did it dry you could damage them? My dad owned a transmission shop so I saw a lot of plates/clutch packs & stuff. Do these big bikes tend to have issues w/ the 1st/2nd gear clutches from like feathering the clutch as they start moving? I'm asking/guessing b/c I've heard of other bikes wearing the lower gears out over time? Thanks for the share... peace

[@BrickHouseBuilds]

Well the clutch is not specific to gears unlike a car transmission. A car has drums, bands, clutches, and valve bodies to transfer force so a lot more can go wrong. For motorcycles it is much more simple with a single basket similar to the way a cars manual transmission clutch works.

[@diggy-d8w]

I do like watching someone w/ know how GiTing - R- Done ! Thanks for the work & time

[@mikearmstrong2488]

I have left the sump bolt out whilst filling the crankcase with oil - I got a phone call and I tell you what I will never do that again !

[@BrickHouseBuilds]

🤣

[@kencreten7308]

I might even buy a bike like this... but. You know, I'd need the clutch replaced.... Oh! you did that! heheh

[@BrickHouseBuilds]

She's dang near perfect 👌

[@katywalker8322]

Are you using the Barnett heavy duty springs? I had them in my 1200. Get to be a bit heavy around town (I once made the mistake of using the Bandit for a local charity toy run - heavy duty clutch and it was fitted with 40mm flat slide carbs - my arms were killing me). Coped with 150hp+ though. Some people use 1 standard spring and one heavy duty spring

[@BrickHouseBuilds]

I am using the two springs it came with. Lever really didn't feel much different at all

[@katywalker8322]

@@BrickHouseBuilds , mine were the heavy duty ones. Looks like they just list the "standard replacement" ones these days

[@chadmarcellay2339]

Looks like the v max needs a new rear tire pretty bad as well as the seat needs reapohlstered.

[@BrickHouseBuilds]

The Vmax will eternally need a rear tire 😎 Not concerned about the seat though. You should see the videos on the bike to see the condition

[@TommyNitro]

How long do you let new plates soak in the oil?

[@TommyNitro]

Never mind. You just stated.

[@paulrooney8164]

Vote for Pedro and all your wildest burnouts will come true!

[@BrickHouseBuilds]

YUUUUSSS

[@robertobatista3582]

Muito bom, parece uma mesa de cirurgia....

[@petethefeet1461]

ya didn't hear me shouting FIIIIILTER ..... lol 👍

[@BrickHouseBuilds]

😅

[@brunobruno1675]

bonjour, j'ai une suzuki 650 bandi 2008 35000km, un problème je viens de changer mon embrayage mais mon blister bouge beaucoup avant que tout reparte, mon bloc n'a aucun problème ou ça et HS ou autre chose ? ??Merci beaucoup

[@neilbarnett3046]

I know in my head that bikes often have an oil-bath clutch, but it still seems odd to see you soaking the friction discs in oil.

[@BrickHouseBuilds]

@neilbarnett3046 well being an oil bath clutch, it's designed to work with oil so going in dry is bad

[@bchdsailor]

Naye problem if target is achieved - I would not call this as errors, just minor glitches

[@BrickHouseBuilds]

Minor glitches indeed 🤘

[@stephenhepburn6374]

should chuck those little screws in the bin,they not needed and a pain if they dont go down all the way

[@BrickHouseBuilds]

They weren't hard to get seated 🤷‍♂️

[@stephenhepburn6374]

@@BrickHouseBuilds they are there to hold springs down just before you put nut on ,suzuki knew they can strip their threads so reduced later bandit to2 holes in spring seat but still had the 3 holes in clutch center. Asyou put your vid on bandit fb forum to help my point was they can and have caused problem fully compressing springs so not letting the nut and washer tighten down fully leading to more clutch slip. Alot of owners know this from experience. I also mentioned there is a difference in steel plates in thickness 5 an6 when in stack on origional suzuki at least,i dont know with barnet plates maybe you can check and inform us all. Also pointing out that changing plates is alot easier to do without removing the whole clutch and putting plates in one at a time is no criticism of you its just easier isnt it ,helps others as what we all answer owners questions for right??

[@stephenhepburn6374]

dont need to remove whole thing,assemble stack one plate at a time ,

[@BrickHouseBuilds]

I prefer to remove and inspect/clean when possible

[@kencreten7308]

You're not dumb, Buddy. I know dumb, and you are not it. I have the dumb, because sometimes I cannot brain.

[@waynepaterson450]

I’ve changed my oil and forgotten to put the sump plug back in. 🤦‍♂️

[@BrickHouseBuilds]

That is definitely something I could see myself doing lol

[@donstorm8460]

Write out order of operations

[@stevenwarner7348]

What what what ??? Painting those chrome covers (per your instructions.) Thank you so much. Still working on West Virginia's carbs. Someday tho. 〰✨🌿‼👍‼🌿✨〰

[@BrickHouseBuilds]

🙏🙏

[@stevenwarner7348]

@@BrickHouseBuilds Thanks B.J. Course I have not started (very much) on my 1998 Bandit. I hope soon tho. ~ And so at this time, your bike is for sale. I am surprised no sale yet. I totally understand. I hope all the video's will stay available after the sale? W/O me bugging you about this bike can you confirm? I would be a buyer but then no ~ for obvious reasons. Thank you so much. Steve (from New Hampshire)

[@GearHeadGeeks]

You made a ton of extra work for yourself. You should not have taken out the basket. Just remove to retaining ring and you could have disassembled and reassembled the clutch like normal clutches without any alignment problems. But what is done is done. Just saying. Also I would have made a big mess out of the oil.

[@kencreten7308]

V-Max... ran out of GAS? What is it like a musclebike or something? heheh. I had wonderful Honda Superhawk, 1998. 90 degree v-twin... 1000cc... what a great bike. unfortunately 30mph, and a small tank. 90 miles was about it.

[@BrickHouseBuilds]

😅 yeah just the STRRRAAAANGEST thing

[@amitkeynan922]

why don't you carry a gas siphoning tube...?

[@BrickHouseBuilds]

I've never known anyone to carry one of those

[@amitkeynan922]

@@BrickHouseBuilds It takes up very little space, and is worth its weight in gold if you have a motorcycle with a malfunctioning fuel gauge, look for "Self Priming Siphon Hose"

[@laurencehastings7473]

Clutch reassemly difficulties , understandable. Oil filter issues, forgiveable. Running out of gas, hilarious.

[@BrickHouseBuilds]

Agreed lol 😆

[@randys7693]

If you guys stopped doing burnouts your clutches would last longer :D

[@BrickHouseBuilds]

I have yet to do a burnski on the Bandit!

[@paulwhite7475]

Dont sell it .

[@BrickHouseBuilds]

It will be missed but it's the right decision

[@Plague-rq2lg]

was that nut uggad to spec lol

[@BrickHouseBuilds]

It was. 1.5 uggas

[@nickvinten7803]

Show 1 mechanic who’s never blundered and I’ll show your a liar 😊

[@BrickHouseBuilds]

Exactly lol

[@MrPotatochips4]

Mercury retrograde.

[@kevinguccione1778]

i remember when i didn't have the clip pliers so i use a normal one and now the circlip is on the stratosphere lol

[@BrickHouseBuilds]

@@kevinguccione1778 You'll have that 😅 I've launched some fork caps before

[@JustanOlGuy]

[@BrickHouseBuilds]

👋