GS400 restoration project

[MarkoGS400]

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

Hi, that GS truly looks sweet! =D>

I have been able to work with my bike for only one weekend for this autumn/winter and disassembled the whole body and I'm going to sand blast the body and tank and later I'll take it to painter. Any advises for that procedure?

I assume that your bike is made for US markets and there are several other versions in european market? Since my GS400 is produced for Finnish/Scandinavia markets I think that there are some differenced with your bike. Is there any list where I can see all the differences with US-German-Finnish models?

Right now I'm missing starter and some parts from starter clutch set and contact breaker. Also some smaller parts aremissing but I can buy those when I'm assembling this bike.

I also noticed that my bike have had these small decals on the tank sides http://www.suzukicycles.org/photos/s..._GS400_450.jpg. I can see that your tank is only painted. Any idea where I can find these decals?

I also have a little problem finding out if my front fender should originally be chrome or painted red. I found lots of pictures (from Finnish GS400) where there is red fender but there is also lots of pictures with chrome fender!

Next thing I'm going to do is break that motor apart and see whats going on in there. So I would need to find all gaskets, oilseals and bearings. Can't find those anywhere! Full gasket-set would cost well over 100€=$125 at my local parts dealer! Any idea where I could order those for cheaper?

I'm sorry about my bad English and these terms

[ptm]

In addition to suzukicycles.org, another site that is useful is Alpha Sports http://www.alpha-sports.com/suzuki_parts.htm It uses actual Suzuki part numbers which is helpful. It also shows another part that fits when the original is no longer available.

I don't know any where to find differences between the models sold in different countries. Search the Web - you might find something.

Complete gasket sets are available on eBay. here are a few I found with a quick search. They're not cheap, but better than buying them individually.

http://cgi.ebay.com/ebaymotors/Suzuki-GSX-400E-Complete-gasket-set_W0QQitemZ2487088287QQihZ014QQcategoryZ34284QQrdZ1QQssPageNameZWD1VQQcmdZViewItem

http://cgi.ebay.com/ebaymotors/Suzuki-GS400-GS-400-GS425-Complete-Gasket-Set-New_W0QQitemZ150043064376QQihZ005QQcategoryZ35595QQrdZ1QQssPageNameZWD1VQQcmdZViewItem

http://cgi.ebay.com/ebaymotors/COMPLETE-ENGINE-GASKET-SET-SUZUKI-GS400-77-78_W0QQitemZ200050465959QQihZ010QQcategoryZ35595QQrdZ1QQssPageNameZWD1VQQcmdZViewItem

You can find a lot of good used parts on eBay - just look carefully at the seller's feedback.

The link to your decal picture didn't work, but I had none on my tank. There were decals (GS400) on the black side panels that I removed (when I was young and foolish). I found a company that made reproduction decals that were very similar, but I can't find their link right now. I'll look more later.

All the 400s I've seen have chrome front fenders, but there may be some that don't, or someone may have painted over the chrome.

No need to apologize for your English - it's very good.

Have fun.

[gerkin]

HI MARKO are you in europe?

http://www.gs-classic.de/index1e.htm

good site use babel fish to translate

[MarkoGS400]

Here is a link to a bike that have decals on tank. I can see that my bike have got decals in tank but some one have taken them of.
Here is a link to a bike that have red painted front fender. I dont know if that is original fender but my fender is also painted red. I'm not sure if I have to buy a new one because thats not in so good shape. By the way this bike doesn't have decals on tank but it's not so original looking anyway.

I've been looking part numbers from that Alpha Sports site and it's been very helpful.
Thanks for those ebay links. I might consider ordering some of those and hopefully the postage fees and taxes aren't so big.
Thanks Gerkin for that German site! Learnt something new

[BentRod]

just as lost

Hey Mark

I just bought what is supposed to be an 81 GS400, and I'm also struggling with finding parts.

Most of my problems are front-end related, and some parts of the bike are held together with rubber bands and twist ties. I'm having trouble with my front forks and front brake.

I have some metal/body work experiance. It may be possible to salvage the old front fender, assuming it is still mostly metal and not rust.

If you can post more pictures of the front fender I can have a look and see if I can tell you anything useful.

BentRod

[MarkoGS400]

If you can post more pictures of the front fender I can have a look and see if I can tell you anything useful.

BentRod

Right now I don't have a pisture of that front fender but the biggest problem is that I want it to be chrome not painted red. So I think that I would get it much cheaper to just buy new one than finding a good chrome company.

I'm still having hard time to find that gasket set
There is one full gasket set for sale at ebay.com but shipping would cost douple of the bidding price!
Any idea where I could try to ask for it?

[BentRod]

ya.. unless you happen to have sulfuric acid, a couple of large glass or prosciline bowls, and a large chunk of chrome, go with buying a new one.
IF YOU DO I can send you instructions.

by the way. I got dibs on OldSchoolOrange's fender... hahaha

What is the engine model? ie mine is an 81' GS40X

[oldschoolorange]

there are some sites around selling gaskets for your engine

http://street.parts-unlimited.com/7/1638/2500418

http://www.cyclewareables.com/pages/street_motorcycle_gasket_sets_individual/suzukistreetgasket.htm

http://www.patternparts.net/stock_refine.asp?model=104&category=11&model_go.x=14&model_go.y=14

I am going to post pics of me fixing this thing up so I guess we can all help one another

[gerkin]

great another 400

nice to see a few 400s here!

[MarkoGS400]

there are some sites around selling gaskets for your engine

http://street.parts-unlimited.com/7/1638/2500418

http://www.cyclewareables.com/pages/street_motorcycle_gasket_sets_individual/suzukistreetgasket.htm

http://www.patternparts.net/stock_refine.asp?model=104&category=11&model_go.x=14&model_go.y=14

I am going to post pics of me fixing this thing up so I guess we can all help one another

Thanks for those links!
I think that patternparts is the cheapest. 50£ shipped to Finland.
Good luck with your project!

[MarkoGS400]

This problem with starter again...
Which starter I should buy? The one manufactured my MITSUBA or the ND.
My parts list shows both of those but because I don't have that original starter so I'm not sure which one of those is the right one.
Or does it have any difference which one I use?