GS400 restoration project

[MarkoGS400]

Hi!

I am new user to this site and reason why I am here is that I bought a little project bike.
Suzuki GS400 year 1978!

Its totally detached in small parts in couple of boxes. Well, atleast it was cheap :-D


Here's a list of my questions:

Is there any good project stories about this bike?
What parts from other models are equal to this bike?

I'll add my questions here when I have time to start this project.

Here you can see couple of pictures from the day I bought this beauty

[tfb]

Welcome to the GS Resources, Marko... you've come to the right place!

Have you tried using the 'Search' feature to look for previous posts relating to GS400's? That would be a good way to start.

(BTW, I tried to follow your link to the pictures of your project, but simply got a 'page cannot be displayed' message.)

All the best,
Mike.

[MarkoGS400]

Welcome to the GS Resources, Marko... you've come to the right place!

Have you tried using the 'Search' feature to look for previous posts relating to GS400's? That would be a good way to start.

(BTW, I tried to follow your link to the pictures of your project, but simply got a 'page cannot be displayed' message.)

All the best,
Mike.

Yeah I did try the search and I found many interresting topics that I'll will truly come back later on.
I'm preparing for forthcoming detaching and repairing and so now I'm going to do is try to find parts that I know that I'll need later.

So the important question is that: What parts from other models are equal to this bike?

I haven't seen so many GS400 parts and would be curious to try some GS425/450/500... parts but I it's hard to buy those without knowing if they will fit.
So my bike is made in 1978 so does the manufacturing year have any matter on fitting parts?

And that link. It works fine for me when I try to copy&paste the address but klicking is not working.

So try copy&pasting this to your browser:

https://www.tkk.fi/users/mrantone

[Nessism]

Your best bet to find out if parts are interchangable is to use the Suzuki parts catalogue and look up the different part numbers and compare.

http://www.alpha-sports.com/suzuki_parts.htm

I can tell you that the 400 and 425 were very similar, the 450 is a little different and the 500 is a lot different. I'd be surprised if ANY parts interchange between your bike and a 500.

Good luck.

[Nessism]

Just got back from checking out the photos Marko and I must say you have quite a big project on your hands. From the basic condition I'd say you better think long and hard about how deep you are willing to get into it. Those pistons have lots of blow-by so you are going to have to at least, re-ring it.

I say this from experience since I cleaned up a GS450 earlier in the year. Paid $200 for the bike and continued to spend $600 more on: tires, tubes, chain, sprockets, battery, gaskets, paint, manual, filters, oil, ect. At the end of the day, I had more into the bike than it was worth and mine was WAY less work than you have on your hands.

Good luck and keep us posted on your progress.

[staggy]

If you make a list of parts you need I will try and cross reference the parts at work as I work for a motorcycle parts and accessories company.
Good luck with the gs400,my gs425 is nearly finished and it is a great feeling to reserect a bike from the dead.

[tfb]

Yes, it looks like you have lots of work ahead of you there. And as Nessism points out, you will end up spending more than the bike is worth.

But hey, the reason I spend money on my old bikes isn't to make money! It's all part of the trade-off. I spend money, alright -- but I get lots of pleasure and satisfaction out of doing things right, and getting the machines running better and better.

And as the intro. to the GS Resources says, a GS will always turn heads. They are a classic machine, and in my opinion always worth rescuing from the scrap heap whenever possible.

So set about doing things methodically and properly, get yourself a manual, and you'll have a ball.

[MarkoGS400]

Yes, it looks like you have lots of work ahead of you there. And as Nessism points out, you will end up spending more than the bike is worth.

I know that this will cost a lot but the idea isn't make money by selling this project later but the thing is to get my hands dirty and have fun making this bike running!

About those pistons. Those are maybe the reason why this bike is in small pieces. Luckily the former owner have repaired and redrilled cylinders.

There will be lot of work before this bike is running but hopefully we have at least mots of the parts. Starter and and some small parts are missing and some of the parts are just too rusty to repair.
The will also be a lot of paint work to do so this ain't a small project

Thanks for that parts link!
I already have parts catalogue for GS400C and I have to get that manual. I think this works fine?

[Nessism]

Check ebay for a factory service manual. They usually sell for less than that Clymer and are far superior.

You mention "redrilled cylinders", do you mean they have been bored oversize? Is so, you are going to need oversize pistons and rings as well.

You might want to check out this thread on a guy that is restoring an old GS. He is doing the job the right way: sandblasting the frame and such.

http://www.thegsresources.com/_forum/showthread.php?t=89601

Good luck!

[txironhead]

I know that this will cost a lot but the idea isn't make money by selling this project later but the thing is to get my hands dirty and have fun making this bike running!

That's the spirit that started my obsession with motorcycles! Take my advice, though: Remember that idea when you're sitting there saying "Where the @#$# does this go?" Trust me, it'll all be worth it when you finally do get it on the road. Knowing you're riding a bike that YOU put together, YOU rescued from the grave and YOU know front to back is one of the best feelings in the world.

[MarkoGS400]

Check ebay for a factory service manual. They usually sell for less than that Clymer and are far superior.

You mention "redrilled cylinders", do you mean they have been bored oversize?

Yeah, by redrilled I meant that the cylinders are bored oversize and because of that it certain that I need correct size pistons. Of course.

txironhead: Sounds great and that gives me spirit to continue this project!

I ordered that Clymer manual and I hope it will help me forward.
I'll keep you posted when this project continues!

[gerkin]

ive got a gs400 too

ive got a gs400 im gonna facelift and tidy up,,how you getting on with yours ,perhaps we could share tips and advice

[ptm]

They are great bikes, and fairly simple to work on.

As far as parts availability, it can be a little rough, since there aren't too many of them out there. The engine is essentially the middle of a GS750 of that era, so the pistons/rings are interchangable, and the front brake caliper/rotor was used on some other models, so you can get rebuild kits.

The '77 and '78 are virtually identicle except for some minor jetting; the crossover on the exhaust, and a few other things. I detailed most of that in another thread you should be able to find with a search.

The manual will work fine, but you should look for a factory manual as well. Here's one on eBay that should cover your year - reasonable price as well. http://cgi.ebay.com/ebaymotors/SUZUK...spagenameZWD1V
Here's another slightly more expensive... http://cgi.ebay.com/ebaymotors/1976-...spagenameZWD1V

I think they should cover the '77 and '78, but you might ask. There are also several owners manuals on eBay that might be usefull.

I have part number cross reference software, so if you have specific parts you want to know about interchangability on just post the question and I'll probably see it adn let you know.

Good luck and have fun...

[ptm]

Also, let me know if you need info about how things go together, wire and cable routing, etc. I can send pics.

Here's my '77 GS400 for inspiration. Bought it new in spring of 1977:


and links to a few more pics:

http://home.sprintmail.com/~pmusser/sitebuildercontent/sitebuilderpictures/400sm.jpg

http://home.sprintmail.com/~pmusser/sitebuildercontent/sitebuilderpictures/400engsm.jpg

[gerkin]

my 400

german model with gs 425 running gear /paint