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Just got a 1982 GS400E

  • Thread starter Thread starter dude99
  • Start date Start date
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dude99

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Hello all, I was in need of some transportation so I traded my dirt bike for a 1982 GS400E. Its in decent enough shape, although I'll have to do something about the previous owners rattle can job....
Anyways it has an issue or two, the main one is one of the previous owners fitted pod filters and an after market 2 into 1 pipe and it will not rev past 5000 RPM, just breaks up and crackles. Pretty sure that it wasn't jetted up. I had a look at the needles and they were on the bottom clip, so someone at least knew that they had to richen it up. The previous owner just had the carbs cleaned at a local shop, and they are definitely spotless however I haven't been able to find out what the stock jets are in this so I know where to go. I did some reading and was thinking that going up 2 sized on the main should put me in the right range. Any thoughts? and yes I've already searched and read what I could find.
On a side note is there a link somewhere to a repair manual for this bike? I haven't been able to find one.
 
What size mains do you have in there right now? 100?

I can front you some 120s. That'll put you into the upper end of what you're going to need, but it's something to try without ordering in something you're not going to use.
 
Not sure whats in there at the moment, but I would imagine, based on the way its running, that its probably the stock jetting. Thanks for the offer for the jets, I love communities that share, seems I stumbled into a good one. Where abouts are you located?
 
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hmmm, seem to have an issue here. The repair manual lists the stock main as 117.5 however the fiche at the local dealer lists the stock as 120..... Which is it? can't really jet up if I don't know whats stock....
 
I'm right in the heart of the city, near City Hall, but I work at UBC.

Some of these model specs are a little nebulous. According the chart on BassCliff's page, 120 seems likely. That being said, even if it was 117.5, going up to 122.5 or 125 wouldn't be unrealistic for pods. If you pull your jets and you have something smaller than 120s in there, let me know and you can try mine.

I've heard various opinions on jets, but the majority have indicated that starting with the largest main jet and working your way down using plug chops is the safest way of going about your business. Makes sense to me, as an overly lean condition is more detrimental, more quickly than an overly rich condition.
 
hmm, UBC is quite a ways from me, I'm out in mission.. oh well.. thanks for the offer though. My bike has pods as well as an after-market pipe... is 125 still a good starting place or should I go bigger?
 
Koolaid Kid and TCK (TheCafeKid) are good carb guys...and KK is on here quite a bit these days. TCK seems to be on a hiatus

A good rule of thumb is +2 for pods and +2 for a freer running header. So if you have both, then up four sizes, 117.5 to 127.5 would be the upper end. That sounds really large to me though. Just two sizes on the main would put you to 122.5. I suppose you could split the difference and start at 125 and take it from there. Jets are not that expensive, and seeing as you have a twin, cheaper yet.
 
Just need a confirmation here, the main jets in my bike is a N100604 (Big flat round) right?
 
Not sure about your number, but the parts diagram at Boulevard suggests yours should have the 102.22 or small, round jets, and in a 115. OF course, that is for the '82 450. They have no listing for a 400E, but the 400 and 450s share the same carburetor type...BS34SS
 
BigD_83 said:
Not sure about your number, but the parts diagram at Boulevard suggests yours should have the 102.22 or small, round jets, and in a 115. OF course, that is for the '82 450. They have no listing for a 400E, but the 400 and 450s share the same carburetor type...BS34SS
Click to expand...

Check the fiche at CMSNL (might be under GSX400) they were the same crabs but not have the same jets

http://www.cmsnl.com/
 
Update, pulling the carbs apart.. it seems that there are 130 mains in it...
 
130 IS four sizes larger than stock already...

In my opinion, plug chops are the way to go right now, but that's going to be difficult if you can't get it opened up past 5000rpm/run it at WOT.

Can you get it to break through the wall if you open up the choke when it starts to crackle?
 
117.5 is stock,
130 might be compensating for something else like really small pilot jets or missing air jets.



Take the pod's off and put something accross them to restrict air, like a rag and clamp them back on. This should ritchen it up a lot! IF it acts better then you have an idea of the direction you have to go.

what was the pilot jet ? 42.5 is stock.


what was the float height?

By chance was one of the diaphram's pinched and not raising the slide?

What about the air jet's on the intake side of the carb? are they still there?


Often times a bike without an airbox acts the same way until the carb is restricted a bit or jetted for so much open air.


Have you checked compression or done valve clearances yet?



Take a look at this site as well for part numbers.

http://www.cmsnl.com/suzuki-gsx400-1981-ex_model13617/partslist/
 
Maybe a little OT but what is the purpose of the air jets at the mouth of the carb?

I still dont get what they do really.





As far as you jetting issue goes I would jerry-rig something to restrict the air flow to see if it makes the bike run any better. Like a tshirt around the pods or something. If the bikes runs as bad than you know the problem is related to something other than the jetting vs air...
 
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