DO THE TON

Blood Sweat Tears and Grease => Projects => Cafe Racers => Topic started by: cierrecart on Nov 15, 2012, 22:14:03

Title: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Nov 15, 2012, 22:14:03
A few years back I made the transition from a modded scooter, to a restored 67 Suzuki K15 "Hillbilly", to a slightly cafe'd RD350. 
Well, then I got into triathlon, got obsessed and just had to have an expensive bike, so I sold the bikes that had motors.   Still obsessed with triathlon, but after stumbling across the Holiday Customs  GN400 brat bike, I knew I had to get another project.
http://www.pipeburn.com/home/2012/10/22/1980-suzuki-gn400-holiday-customs.html

With that bike as my inspiration, I started watching CL, and found one fairly local...and $200 later I had this:
Coming home crammed in my minivan:
(http://img.photobucket.com/albums/v76/undertheradar/FF4F0780-8831-42A4-B22E-3BF4B37D48D1-1584-000002F6DC0B8B6B.jpg)

FUGLY!
(http://img.photobucket.com/albums/v76/undertheradar/FC79EC4E-AB2E-4264-B85D-355E189ED2B8-1584-00000330B46DF463.jpg)

The good news was that the bike has been in a storage space for a long time, and its in decent shape.  Motor turns over just fine, everything works....but it doesn't run.   The guy I bought it from (the original owner) said he had just had carb work done on it 3 months ago and it was running great (dont they all say that?) but that he'd left the petcock on when he put it away those months ago and that the jets were probably clogged.  I took a leap of faith and decided to tear it down first, then work on getting it running once I was all done.
The other positive is that it has a clear title.  (Definitely a bonus after the hoops I had to jump through with the Hillbilly!)

So, the plan is to go for a cafe/brat hybrid.  Keeping the stock tank, ditching the airbox/sidecovers,  lowering the tree on the forks to fit clipons above it, cutting the rear frame and adding the DCC rear loop and brat seat.  Plan was to get some big ol' Firestones, but the rubber on this bike is in great shape so I'll run them for now.  Ditching the tach and center console section and just running the speedo.

Already have a sizeable order in to Dime City.   Hoping to have the motor out and frame ready for paint over the weekend.
Budget is the primary concern....I'd like to stay under $1000 when all is said and done.  I have very little time to ride, so this will just be an around town errand runner on the weekends kind of bike.   I want it to look good and be fun.


Here she is stripped down24 hours later.   Forks are up in the trees to see what kind of stance I'd like.
(http://img.photobucket.com/albums/v76/undertheradar/AB008ED9-A757-455B-BA7E-D19E8DEACDB7-2413-0000048D70DB80EC.jpg)

(http://img.photobucket.com/albums/v76/undertheradar/AED3F80C-F1FC-48CB-B3FB-A909697B3C80-2413-0000048D750160F2.jpg)
 
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: Chewy on Nov 16, 2012, 18:45:27
Small world. Our mutual friend Randy showed me these pictures yesterday.

Cool Project man!
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Nov 16, 2012, 20:53:24
haha...thats crazy.  Tell that little bastard I said hi.  :D



So my very first part came in the mail today so I did a quick mockup.  Black anodized clipons.   They look really nice and fit perfectly.   I think I'm gonna really like the different angles I can get with them.
(http://img.photobucket.com/albums/v76/undertheradar/200660C9-651C-4EFD-B56E-0D4B70D783AA-3160-000005F147328FE1.jpg)

(http://img.photobucket.com/albums/v76/undertheradar/E6CE0C76-56BD-4158-A778-02CFA9253926-3160-000005F14BA29540.jpg)


I've also ordered a few more odds and ends like the tach plug for the motor since I'll be doing without it.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Nov 20, 2012, 17:50:09
Decided I wanted to try shortening the forks internally.   This is just a mockup with a 2.5" spacer in there.   I think I might do 3" instead just because this bike had such long forks to begin with.   There is plenty of room in front of the wheel and no other contact points, so it should be okay.
(http://img.photobucket.com/albums/v76/undertheradar/BAAEC926-FF33-44F9-B009-3DC8393B0796-1565-0000029AD8A94AD1.jpg)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Nov 26, 2012, 20:39:14
All torn town.   Also shortened the forks by 3", cleaned them up and painted the lowers.   Currently waiting on lots of parts.

(http://img.photobucket.com/albums/v76/undertheradar/943ED892-8BE7-492E-BB55-583EF35D68AD-2625-0000055179A33182.jpg)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: reesea17 on Nov 27, 2012, 23:26:32
If you don't mind me asking I'd like to get a few bits of information about how you shorten the forks internally. 

I just bought a CB450 and am looking to lower it by 2" overall and am wondering if it would be the same as you did here or not.  Very broad question I understand.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Nov 28, 2012, 04:45:30
Parts have started to arrive!
(http://img.photobucket.com/albums/v76/undertheradar/4FACE628-180B-4483-8199-B1243C74F1B8-3501-000006DDC04BC34F.jpg)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Nov 28, 2012, 18:14:40
If you don't mind me asking I'd like to get a few bits of information about how you shorten the forks internally. 

I just bought a CB450 and am looking to lower it by 2" overall and am wondering if it would be the same as you did here or not.  Very broad question I understand.

Sure thing.  I used this as a guide:
http://www.xs650chopper.com/2009/06/mulligan-machine-lower-your-xs650-forks-low-buck-garage-tech/

Everything was almost exactly the same on my bike, and I think most Japanese bikes from that era are very similar.  Hardest part was figuring out how to make the tool to hold the damper rod during disassembly.

I used a 2" and 1" spacer on each side.  Found them at Lowes in the bolt drawers.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: massey65 on Nov 29, 2012, 10:40:15
When I took my GN forks apart I just put the springs back in then pressed down from the top with an impact wrench and they came loose. I have a 1980 GN400 as well.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Nov 29, 2012, 16:26:34
Yeah, I'd heard that would work, but I dont have any air tools or impact drivers right now.  Using a bunch or extensions and a 17mm bolt head worked well though.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: misteroddjob on Dec 02, 2012, 19:38:23
Subscribed. Looking forward to seeing the end result.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Dec 03, 2012, 17:29:12
Got my rear Firestone in today, and the wheels are all painted along with the rear sprocket/hub assembly.  Just waiting on my new tubes and rim strips to get here so I can take them to get mounted. 
(http://img.photobucket.com/albums/v76/undertheradar/44CF3F62-0F21-4507-BDB5-64C81065CD1C-6372-00000F8DB455AD05.jpg)

(http://img.photobucket.com/albums/v76/undertheradar/594FFF85-2DA9-4297-BE0A-17475AF1FD88-6372-00000F8DAFF88615.jpg)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Dec 07, 2012, 21:06:16
Today I spent some time stripping the tank and de-tabbing and cleaning up the frame for welding and paint.   Meeting up with my buddy on monday and he's going to teach me to weld a bit and help me get the rear hoop put on.
(http://img.photobucket.com/albums/v76/undertheradar/275102A4-E951-4DEB-9EC3-48B42C4CFB0B-9529-000015A1C6AA19E1.jpg)

I've decided to not go with the DCC seat and pan.  I just didn't like how much moifying of the frame it would take, and it was really too long.  I'm going to go this route and utilize the factory kick up to my advantage:
(http://www.crdmotorcycles.com/var/ezflow_site/storage/images/media/images/_a8i0028seleccionbis2/622-1-esl-ES/_a8i0028seleccionbis_detalle.jpg)

Tubes also came today so I should have my tires mounted up soon, and my buddy back east is powdercoating a box of parts I sent him.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Dec 10, 2012, 23:32:00
Had a great day with the project today.  Started off by getting the tires mounted, sprayed some bedliner on the bottom of the tank, then later this afternoon went over to a buddies house where he not only welded up my rear hoop, but also taught me how to weld.   Had a freaking blast!

Wheels and tires:
(http://img.photobucket.com/albums/v76/undertheradar/45B2E4FB-77D7-4C2C-8359-5A8752A8C423-10994-000019B62172A4EF.jpg)

Tank:
(http://img.photobucket.com/albums/v76/undertheradar/C8193EEF-8829-4EA0-92BB-96951898E3AC-10673-000018A941355F7D.jpg)

Figuring out the length:
(http://img.photobucket.com/albums/v76/undertheradar/7B1D66EC-9082-45BD-8C94-8103F79AFD84-11364-000019F0D7CE4BC9.jpg)

Slugs fitted:
(http://img.photobucket.com/albums/v76/undertheradar/16E88072-EDAD-4C1B-9C88-778D0575AAEA-11364-000019F0C60A08B4.jpg)

My buddy Adam at work:
(http://img.photobucket.com/albums/v76/undertheradar/6CFD8826-EBCC-4FF8-B3ED-349B84559D2D-11364-000019F0C066D2C2.jpg)



Here's me learning to stick metal together.
(http://farm9.staticflickr.com/8500/8262195273_7de186a32d_c.jpg)

And grinding it down so it looks decent, lol.
(http://farm9.staticflickr.com/8353/8262192255_0ee9073f82_c.jpg)



Next step is to finish cleaning up the frame and I'll be painting tomorrow.   Then its assembly time.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cory.ahlersmeyer on Dec 11, 2012, 04:00:24
I'm watching this show.
My buddy has a GN400 that he knows very little about and I may help him get it going after graduation this weekend.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Dec 13, 2012, 12:25:38
She's rollin....
Ordered some new all black shocks that are an inch longer.  Front height isn't set yet, but should be pretty close to this.
(http://img.photobucket.com/albums/v76/undertheradar/75E51F16-1D3B-4D00-BBF5-020CB5E818C8-12732-00001C88E7404754.jpg)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: WhyNot on Dec 13, 2012, 13:09:44
This is kewl.......I likey..........!!!

What did you paint the wheels with, pleeeezzz?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Dec 13, 2012, 16:07:13
Duplicolor bedliner.  Cheap way of giving a tough finish that hides imperfections.  Used it on the frame too.  Powder coating just wasnt in the budget for this one.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: shamus on Dec 13, 2012, 16:19:29
I like where this is going.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: veaone on Dec 13, 2012, 16:41:07
It looks great. Love the agressive stance it has.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Dec 13, 2012, 22:56:45
Got my powdercoated stuff in the mail, so I bolted a few of them on.
(http://img.photobucket.com/albums/v76/undertheradar/76FC75FE-2FD2-4B6E-B114-6A1715C708F3-13274-00001DF956941F19.jpg)

(http://img.photobucket.com/albums/v76/undertheradar/41E5E4F8-A04C-4518-A74C-54A9B20591F8-13274-00001DF612AB380C.jpg)

(http://img.photobucket.com/albums/v76/undertheradar/D7C0448C-7267-421A-BEA8-E5FC29EDE5C4-13274-00001DF60AF5722A.jpg)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: WhyNot on Dec 14, 2012, 08:38:35
It looks like you removed the sprocket hub and sprayed the whole thing with the bedliner, spokes and all.......would I be correct?

They really look good......seems, thats gonna be my course of action on my wheels too.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Dec 14, 2012, 14:02:55
Yup...exactly what I did.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: WhyNot on Dec 14, 2012, 19:16:03
Yup...exactly what I did.

kewl.................. 8)

What kind of prep did you do?

Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Dec 15, 2012, 01:21:51
Cleaned really well, then wire wheeled it and scuffed with a scotchbrite pad. 
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cory.ahlersmeyer on Dec 17, 2012, 16:12:00
You happen to have the GN400 manual?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Dec 17, 2012, 21:59:07
Nope, no manual.


I was out of town this weekend so I didn't get to work on the bike, but today I got a seat pan fabbed up.   
(http://img.photobucket.com/albums/v76/undertheradar/8150EE1F-10E0-441B-A3B5-154844CA4814-2389-0000040A694086D1.jpg)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Dec 18, 2012, 21:39:46
Cut and shaped a Walmart workout may today.  Glued 3 layers on, cut to shape then used a flap disc to shape it a bit.  Should be good enough.  I plan to have it professionally upholstered.  Looking at black leather/vinyl with red stitching in either tuck n roll or diamond pattern.

(http://img.photobucket.com/albums/v76/undertheradar/B929CF20-D2EC-49FC-87E0-FF21AEBAF33D-3023-00000578E0707983.jpg)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: shamus on Dec 19, 2012, 00:29:18
Cut and shaped a Walmart workout may today.  Glued 3 layers on, cut to shape then used a flap disc to shape it a bit.  Should be good enough.  I plan to have it professionally upholstered.  Looking at black leather/vinyl with red stitching in either tuck n roll or diamond pattern.

(http://img.photobucket.com/albums/v76/undertheradar/B929CF20-D2EC-49FC-87E0-FF21AEBAF33D-3023-00000578E0707983.jpg)

From the photos, it looks like you extended the foam well past the seat pan. Are you planning on bracing this in any way? I don't think it will hold up over time if it's upholstered as is.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Dec 19, 2012, 03:37:53
That's exactly what I did.  On this bike, the cross brace is raised up quite a bit, and I didn't want to have a bend in the pan and foam at that point.  The "tongue" you see in the foam will be cut back a tad before covering, but just like in the Holiday Customs bike that inspired this, it will have an angled back cut towards the front of the pan.  I won't be sitting way up there anyways, so it should hold up fine..

(http://4.bp.blogspot.com/-wbHYclNTI34/UIVQjU7pwGI/AAAAAAAAFig/VZBQY6gVjJ4/s1600/Holiday_Customs_Suzuki_GN400_Moto-Mucci+(3).jpg)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Dec 19, 2012, 22:22:51
Dropped the seat off at a local mexican father and son upholstery shop that had fantastic reviews on Yelp.  It will be leather look black vinyl with a black piping border and red quilted diamond stitching.  Should take about a week and he's charging me $125.  I little bit more than what I was hoping to spend, but it's still way less than what I paid for the original pre-made piece I was going to use.

Got my taillight/plate bracket today.  Swapped in a 6v bulb and it works great.

(http://img.photobucket.com/albums/v76/undertheradar/6BCE917E-1FCE-446C-AE3F-B7B7903268CB-3795-000006D85531FCD4.jpg)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Dec 21, 2012, 16:59:09
(http://img.photobucket.com/albums/v76/undertheradar/F90E3D5A-2ECA-404B-A1BA-4ADC0D281CF1-4726-0000096E0635FF5A.jpg)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: Ritz cracker on Dec 21, 2012, 20:13:56
the tires look huge,  so tuff
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: massey65 on Dec 21, 2012, 20:24:29
Are those street tires? Will you ride it on the street good with those?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Dec 21, 2012, 20:41:42
Are those street tires? Will you ride it on the street good with those?

The rear is a Firestone ANS, the front is a Dunlop K70.   I suppose they're both like a on/off road tire.   This will only see pavement....I went solely for the looks.  :D



Here she sits after an afternoon of work.  Engine is all painted.   Bedliner on the bottom half, flat engine paint on the upper.   I brushed a few of the pieces to tie in with the tank and sanded the upper fins.  Also got my rear signals mounted, as well as my new shocks from Mikes XS.   The extra inch on them did a great job setting the stance I was looking for.

Next up is getting the motor in the frame.  Ugh.

(http://img.photobucket.com/albums/v76/undertheradar/F9528A0C-1B8A-439F-967E-75E84ABC57D1-4726-00000984A1E99E34.jpg)

(http://img.photobucket.com/albums/v76/undertheradar/BF695A06-0225-46BE-82A9-7C1C1C860524-4726-000009849D559D2B.jpg)

(http://img.photobucket.com/albums/v76/undertheradar/E039270B-29C8-4594-9EA6-3FCC3BBB4169-4726-00000984A5ED72CC.jpg)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Dec 22, 2012, 17:42:04
Good progress today!  Upholstery shop called and said they were done.  Holy hell did they do a fantastic job!  I love it.  It's simple and clean with a slight nod to seats of the late 70's.  I put some threadserts in the pan and bolted throug a cross brace as well as used a pipe clamp in the back. 

I also wrestled the motor back in the frame with no major casualties! 

So, next up is rebuilding my caliper, tearing down, cleaning and rebuilding my carb, then start putting the wiring harness back in place.
(http://img.photobucket.com/albums/v76/undertheradar/18CCD459-F3F9-4B39-B0C2-BCAFC50538F9-5304-00000AE9CB4C1B9E.jpg)

(http://img.photobucket.com/albums/v76/undertheradar/83CA21AC-B680-4B6C-80EF-FE6902C3CF24-5304-00000AE9CDAD4558.jpg)

(http://img.photobucket.com/albums/v76/undertheradar/7A999172-0F26-43F7-8F97-290F2BE98330-5304-00000AE9C7A256D1.jpg)

(http://img.photobucket.com/albums/v76/undertheradar/DD8EA584-3BAD-4EEC-AE16-68563FE429FC-5304-00000AE9D60497D3.jpg)

(http://img.photobucket.com/albums/v76/undertheradar/43DF532B-13F0-4DF8-994F-EEEACF0BEB79-5304-00000AE9D01F080B.jpg)

(http://img.photobucket.com/albums/v76/undertheradar/870E7BEB-CA4C-40C2-AC33-932D4EB2E457-5304-00000AE9D3960ACE.jpg)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: DesertKZ on Dec 22, 2012, 17:46:11
That seat is bad-azz.  Looks sweet  :)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: crackerman on Dec 22, 2012, 18:43:16
Seat looks tits. Digging the old school pattern as well. I'd put a short rear fender on it as well.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Dec 22, 2012, 19:28:04
Thanks guys.  Not sure if I want to run a rear fender.  Thinking of making a simple splash guard instead.  I really like the look of the back end being uncluttered and open. 
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Dec 26, 2012, 18:55:41
Tank decals and header pipe baffle:
(http://img.photobucket.com/albums/v76/undertheradar/9F2B7FD2-34C2-4FF7-8635-96A10524B975-1082-000002EB698D16E1.jpg)

(http://img.photobucket.com/albums/v76/undertheradar/31B21E40-A52C-4FB5-B258-9611EDA55824-1082-000002EB6C7496C9.jpg)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: bravecafe on Dec 27, 2012, 17:31:34
Building a gn400 with my son, kinda similar. Can't wait to see what you do with the exhaust.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: two-smoker on Dec 27, 2012, 19:49:23
You've really transformed the look of that bike... At first I didn't like the chunky rear tire or that you kept the leading axle forks,  but the end result works! I salute you!
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Dec 28, 2012, 02:19:12
Thanks guys!   I'm seriously loving seeing this bike take shape.

Tonight I changed the oil, and my fork oil, and started getting the harness back in place.   Man do I hate wiring!   Even when the original stuff is in great shape, it's a PITA!  I picked up a little tiny lead acid sealed alarm battery to use on this.   I'm going to mount it, along with the CDI and rectifier straight to the underside of the seat pan with some threadserts.  Gotta get that done tomorrow, then put in some fresh gas and see if we can get this baby back to life.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Dec 28, 2012, 22:47:34
Today was a very good day.....she lives!
http://youtu.be/jDCz6DCIea8


After I took that video I got the electronics mounted under the seat, harness ran, and taillight hooked up.   Looks like the headlight is dead, and I need 6v bulbs for my blinkers, and obviously I need to do some tuning...but Im going to put the chain on tomorrow and take her around the block.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Dec 31, 2012, 22:50:54
Hit a small roadblock when I started to try and tune her...air screw head was stripped bad and wouldn't come out so I had to drill it.  Not sure if the threads in the carb are still good, so I have a new screw as well as a used carb on their way.  Also have a few jets and a new headlight on their way.  In the meantime my little speedo showed up.  Cable is now a bit long so I have it snaked around the fork leg a bit...I'll probably source a shorter one later on.
(http://img.photobucket.com/albums/v76/undertheradar/E96EEEB7-FFC8-493C-9158-38F3944FFAAE-4033-00000AE40E3A5570.jpg)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Jan 02, 2013, 21:25:36
Finally got my braided brake hose.  With the rebuilt caliper it bled perfectly and works great!  Also took a shot of how I mounted my electronics under the seat.  You can just see the tiny 1.2ah 6v battery towards the back.   Still need some correct length bolts for the rectifier....currently just held with heavy duty velcro.  Still need to hook up the rear signal wires, which is what you see hanging.
(http://img.photobucket.com/albums/v76/undertheradar/55C8B3E3-F3F3-40D0-8B80-E123E77B6D13-5083-00000DD14FA2343D.jpg)

(http://img.photobucket.com/albums/v76/undertheradar/DBD7A5E1-A69E-487E-8376-66624182F3F5-5083-00000DD14C843ABF.jpg)

(http://img.photobucket.com/albums/v76/undertheradar/4E668C98-B327-4DD6-A72C-4FBB3AE7DFF4-5083-00000DD149985B51.jpg)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Jan 05, 2013, 13:27:14
Three the tank decals on:
(http://img.photobucket.com/albums/v76/undertheradar/D4EC26EE-C7E2-4964-9EB2-1909025745C2-6392-0000110B2689E249.jpg)


Currently waiting on a new exhaust gasket to hopefully solve some tuning issues.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: StryfeS13 on Jan 06, 2013, 00:08:57
Your bike is awesome man. I just picked one of these up from work for $350 and I'm going for that Holiday Customs look as well...Where did you get your tach plug?

What rear loop did you end up using? Which front brake master cylinder is that, mine isnt square like that, it's round? And do you have any clue which spoke wheels fit the GN? Mine came with gold mags!  :'(

Also, what size is the fuse that is in line with the + battery wire? Mine is removed and has no battery, trying to put it back...

Sorry for all the questions. Your build is great, inspiration!
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Jan 06, 2013, 02:23:24
Thanks man.   The rear hoop is the DCC one.   I bought the upswept but ended up just cutting it off before the flat section and welding it to the GN rails where they curve up.

The tach plug I ordered was of I think a GS1100.  They used the same one on a bunch of bikes, just like this:
http://www.ebay.com/itm/1983-Suzuki-SP-250D-SP250-Valve-Cover-Tachometer-Plug-/140673399198?pt=Motorcycles_Parts_Accessories&hash=item20c0c9b99e&vxp=mtr

Master cylinder is stock.   From my research I believe they put the round MC on the 82's?

Not sure on the fuse size...probably a 10a though.

As for wheels, I'm not sure, but this is a fantastic site to look up the various models and part numbers.
http://www.cmsnl.com/suzuki-gn400-t-xt-xx-tx-1980-1981-usa_model15986/partslist/
   Hope that helps!
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: crackerman on Jan 06, 2013, 09:50:20
Did you end up clear coating the tank or is it just bare?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Jan 06, 2013, 14:51:17
It's just bare.   I don't mind giving it a quick rubdown with a scotchbrite to keep what little patina might pop up under control.  Eventually I may do it though...I just want to get this thing on the road.  :)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: StryfeS13 on Jan 07, 2013, 23:26:03
Where'd you get the SS front brake line?

What tire sizes are you running?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Jan 08, 2013, 15:39:23
Where'd you get the SS front brake line?

What tire sizes are you running?


I ordered it off a guy on the bay that will make one whatever length/configuration you want.
Tires are 4.0x18 front and 4.5x16 rear.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Jan 08, 2013, 15:39:37
Well, strike one on registering this sucker..AAA was no help.  Gotta go to the DMV on thursday and start the process there.  PITA, but I've done it before and its not that bad.

But you know what....I'm an outlaw biker now so I said fuck that police and went for a ride anyways.  :laugh1:  I now have 12 miles on her and its running great.   Took a couple pics and a video too.

Only thing I need to do is repaint the lower engine case.   I used the bedliner thinking that it would stay fairly cool down there, but it's getting hot enough to make that stuff sticky.  That'll be another pain, but oh well, I have time to kill until it's road legal.

(http://img.photobucket.com/albums/v76/undertheradar/2A198B32-A22E-4E51-85E8-13EED0602523-695-000001508E44FBAC.jpg)

(http://img.photobucket.com/albums/v76/undertheradar/D986B06C-B209-47C6-9A5E-65D37EEF7D1F-695-0000015095731EEC.jpg)

(http://img.photobucket.com/albums/v76/undertheradar/8BDAECBF-4CB3-4287-926D-8CE416DD8C7E-695-0000015092987C0F.jpg)

https://www.youtube.com/watch?v=HJ8TCL5GPlk

Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: reesea17 on Jan 08, 2013, 19:41:47
How did the tires handle for you?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Jan 08, 2013, 20:01:10
Pretty nice actually.  They give the bike a nice "planted" feel, which for a cruiser like this is perfect.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: massey65 on Jan 09, 2013, 12:34:50
What kind of battery does your bike have? Is the gas tank painted?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Jan 09, 2013, 17:44:15
What kind of battery does your bike have? Is the gas tank painted?

The tank is just raw steel that I brushed slightly.  The battery I'm using is a tiny sealed lead acid that I got from my local Frys.
http://www.frys.com/product/6660524?source=googleps&gclid=CJmi65Cf3LQCFSPhQgod5ysAGg
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: crackerman on Jan 09, 2013, 19:26:27
Came out nice. Big fan of this one. I'd throw some tracker bars on that but that's my 2 cents. Looks like a fun bike.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: massey65 on Jan 09, 2013, 19:39:59
Did you keep it 6 volt? I always have problems with my battery not having enough juice to run my lights.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: massey65 on Jan 09, 2013, 19:40:51
So is the gas tank clearcoated at all? How did you brush it? What keeps it from rusting?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Jan 10, 2013, 00:03:49
Did you keep it 6 volt? I always have problems with my battery not having enough juice to run my lights.

Yeah, it's still 6v.   I'm waiting on my 6v H4 retrofit to get here, so I'm not sure what effect the headlight will have on it, but it powers the tail and signals just fine.  I'm not going to be doing a whole lot of night riding on this, and when I do ride they will be short, so I have no problem keeping it on a trickle charge in the garage.

Quote
So is the gas tank clearcoated at all? How did you brush it? What keeps it from rusting?

No, there is nothing on the tank at all.   I used an 80 grit sanding sponge to get the look I wanted.   A scotchbrite with some Simple Green takes off any patina that forms after a couple weeks.   I've hear a wipe with WD40 will do the same thing.  I may clear it someday, but its not a priority right now.

Quote
Came out nice. Big fan of this one. I'd throw some tracker bars on that but that's my 2 cents. Looks like a fun bike.
Thank man....it's been a blast seeing it come to fruition.  I thought of doing trackers, but I really like having a nice low front end on this thing.   It fits my 5'7 frame perfectly.


Only thing I might change is to swap out the K70 up front for a 4.5 Firestone ANS to match the 5.0 in the rear.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: hillsy on Jan 10, 2013, 07:18:00
Bike looks good  ;)

Idle sounds pretty high in your video - how's the jetting??
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Jan 10, 2013, 16:28:55
Bike looks good  ;)

Idle sounds pretty high in your video - how's the jetting??

It was...I hadn't adjusted it yet.  Jetting appears to be close, if not spot on.  I don't feel any flat spots in the throttle.  Once I put some more miles on her I'll do a plug chop and see if I can perfect it at all.

One step closer to being done, had a painful visit to the DMV this morning to get the paperwork started for the pink slip/plates. $166 fees and first year registration, but I have to go to the highway patrol to get the VIN verified. Basically they run the numbers through the stolen vehicle databases to make sure it's not stolen. They usually have a month backlog, but I got a temp permit that allows me to ride legally till then. :woot:


Oh, and I know I did a good job on it when I had my first mustached hipster taking pics of it from his car as we're riding down the road.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: xunchicrewx on Jan 15, 2013, 12:37:50
Chris you know Im going to give you shit for the vinyl stickers when you couldve sent that tank out here for some proper pin striping. wanker! haha

However this build was awesome! It really made me want to get a second bike but I havent been on mine enough to justify a second.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Jan 16, 2013, 02:03:20
Haha....I was just too impatient to get it rideable.  :)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: massey65 on Jan 16, 2013, 23:47:40
Hey chris the seat you made how did you clamp it to the frame and then upholster it?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: massey65 on Jan 16, 2013, 23:50:49
whats the lenght and width of the seat pan? Id like to do that to mine I just wonder how big a piece of steel I will need. Thanks.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: massey65 on Jan 16, 2013, 23:55:29
OK Sorry just read through your post a little bit more and saw you had it upholstered at a shop so that answers that but where did you get the rear loop?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Jan 17, 2013, 00:19:37
I just had it upholstered there, I built the pan and glued/shaped the foam myself.   I used an off-the-shelf piece of 16g steel from Lowes.   I believe it was 8x24.  The rear section of the frame is 8 1/2 center to center, so the large rear hoop from DCC works pefectly.  The 8" wide sheet gives a nice reveal of the frame/hoop, and you only have to cut and shape the rear half circle and the front section where it narrows down to the tank.


Oh, and it's mounted to the frame via two holes I drilled in the crossbrace.  I used threadserts (threaded inserts installed with a riveter) in the seatpan, then ran two bolts through the holes in the crtossbrace and into the seat pan.   When I bent the pan, I left the bend s a little shallower than they needed to be, which means the screws force it down flush with the frame and rear hoop so no other mounting points are needed.
Hope that helps.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: massey65 on Jan 17, 2013, 19:37:37
Yeah that helps alot thanks. Im in PA we need rear fenders here to pass inspection. Where are you from?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: StryfeS13 on Jan 17, 2013, 22:44:43
I can't figure out if I want a rear cowl on my bike or not...I have a GN400 as well.

I photoshopped the "stiletto" from DCC onto your bike but idk if I like it or not...

(http://i46.tinypic.com/almekg.jpg)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Jan 18, 2013, 01:19:47
Yeah that helps alot thanks. Im in PA we need rear fenders here to pass inspection. Where are you from?

I'm in Long Beach, CA.  Our bikes don't require any sort of inspection, so that's a bonus.

That cowl looks pretty badass.  I'd love to make something similar but removeable.



We had some epically awesome weather this afternoon, so I was able to take her out on her first real ride.  All I can say is that it was awesome.  Rode great, ran great and got lots of looks.  Put about 20 miles on her, and it was a blast.  Took some pictures around the hood.

(http://img.photobucket.com/albums/v76/undertheradar/28479278-94B3-4C32-8F41-66AE25309563-6579-00000DD80169AE5B.jpg)

(http://img.photobucket.com/albums/v76/undertheradar/8B0649A9-AEBA-4D21-BA20-3AC726B5D754-6579-00000DD8054104EA.jpg)

(http://img.photobucket.com/albums/v76/undertheradar/ECD065CD-1C9F-4604-B273-3062EFFAFB60-6579-00000DD7EE42A085.jpg)

(http://img.photobucket.com/albums/v76/undertheradar/81BCA983-36C7-4312-AF6D-63F0BF9658B7-6579-00000DD7E6B594A2.jpg)

(http://img.photobucket.com/albums/v76/undertheradar/34010801-8432-49EA-86A8-DD4DE03302D5-6579-00000DD7EA4AC1B4.jpg)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: StryfeS13 on Jan 18, 2013, 01:29:19
Any exhaust vids with the emgo shorty on it?

Also, how did you use your frame slugs from DCC? I bought some with my rear hoop and IDK what they're for..?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Jan 18, 2013, 02:06:09
I'll have to take a new video with the muffler.  I repacked it and it quieted the bike down quite a bit, but it's still loud in a good way.

I didn't use the DCC slugs, I made my own but they're used the same way.  Basically one end goes in the frame, and the other end slides in the seat hoop.  It's acting as a splice to strengthen the joint where you weld them together.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: DesmoBro on Jan 18, 2013, 02:21:20
Nice Job...It looks BadAss
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: StryfeS13 on Jan 19, 2013, 23:31:17
When you did your forks what seals did you use?

I ordered All Balls fork seals and I believe they were 35X48X11 and they were too tall for my forks. It's almost like I need a 35X48X8 or something...Did you have this issue?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Jan 20, 2013, 00:24:57
When you did your forks what seals did you use?

I ordered All Balls fork seals and I believe they were 35X48X11 and they were too tall for my forks. It's almost like I need a 35X48X8 or something...Did you have this issue?

Sorry, cant help you man.  My seals were in fine shape so I didn't change them. 
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: StryfeS13 on Jan 20, 2013, 01:53:15
Ah damn. Well thanks anyway.

I might have never caught it but which clip ons did you use? And those are 35MM right?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Jan 20, 2013, 03:27:57
Yeah, they're 35mm and they're generic clipons  from the bay.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: reesea17 on Jan 21, 2013, 00:52:26
Are you running the 12" muffler from DCC? How do they sound if so?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Jan 21, 2013, 13:13:16
Are you running the 12" muffler from DCC? How do they sound if so?

I didn't get it from DCC, but it's an Emgo 12".   It sounded pretty good, but I repacked the baffle and it sounds much better., ill post a video soon.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: MJPriceisright on Jan 21, 2013, 13:31:48
beautiful bike man i really like the way its come out.  really digging those tires as well, dual sport is so tough looking.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: massey65 on Jan 21, 2013, 22:14:47
ZDid you need to rejet after putting on the pod filter and sorty muffler
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Jan 22, 2013, 03:37:38
Yep, but only the main jet.  Went up from stock 132.5 to 150 right now.  Running very strong.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: massey65 on Jan 22, 2013, 14:06:47
How was it running before the jetting?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Jan 22, 2013, 17:34:32
Decent, but it was definitely lean.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: gk45011 on Jan 22, 2013, 17:58:10
haha...thats crazy.  Tell that little bastard I said hi.  :D



So my very first part came in the mail today so I did a quick mockup.  Black anodized clipons.   They look really nice and fit perfectly.   I think I'm gonna really like the different angles I can get with them.
(http://img.photobucket.com/albums/v76/undertheradar/200660C9-651C-4EFD-B56E-0D4B70D783AA-3160-000005F147328FE1.jpg)

(http://img.photobucket.com/albums/v76/undertheradar/E6CE0C76-56BD-4158-A778-02CFA9253926-3160-000005F14BA29540.jpg)




What clip ons are those? do you have a link to the seller? Those are exactly what I am looking for for my GS price dependent.

Thanks,
Gary
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Jan 22, 2013, 18:00:28
I know some of you guys wanted me to put some kind of fender on it, so here's a quick fix I came up with using the original plastic inner fender.
(http://img.photobucket.com/albums/v76/undertheradar/B83D713A-1BF1-41B5-A4DF-50ACBC9B43EA-9409-00001507F73F3A11.jpg)

(http://img.photobucket.com/albums/v76/undertheradar/04A9EDD0-806F-43F7-9C0A-78D5D7286C63-9409-00001507F418BBAD.jpg)

Oh, and I put in a neutral indicator (this thing slips in and out of neutral super easy, so I was tired of letting the clutch out a little to be sure.  Meant for a chinese atv, but it friction fit perfectly in the hole in the upper tree.
(http://img.photobucket.com/albums/v76/undertheradar/49F20BFD-B34D-49DA-BCC0-67BA6E116081-9409-00001507F198540F.jpg)

Also put front indicators on:
(http://img.photobucket.com/albums/v76/undertheradar/587AFBF9-825C-443C-8804-952EF1BAF6CE-9409-00001507EDC7D094.jpg)


Just ordered a new helmet today (will be here tomorrow) with a Biltwell bubble shield:
(http://imgs.inkfrog.com/pix/47world/T-50-REDSUPERFLAKE.jpg)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Jan 22, 2013, 18:05:27

What clip ons are those? do you have a link to the seller? Those are exactly what I am looking for for my GS price dependent.

Thanks,
Gary

Here you go:
http://www.ebay.com/itm/Honda-Cafe-Bobber-CB450-CB750-35MM-Fixed-Black-Clipons-Clip-on-Handlebars-/190714880839?pt=Motorcycles_Parts_Accessories&hash=item2c677e2347&vxp=mtr
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: gk45011 on Jan 22, 2013, 19:00:46
Thank you sir! Price and quality shopping.

Project looks great!

GK
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: tafspeed on Jan 23, 2013, 07:47:41
Hi, I have a question regarding the tires: did you use the original wheels? I have mag wheels on my GN and the width of the front wheel is only 1.85. Does a 3.5 tire fit?

grtz
Manu
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Jan 23, 2013, 14:46:35
They're the stock wheels.  The 4.0's fit fine.  I'll be trying 4.5's eventually.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: reesea17 on Jan 23, 2013, 15:23:47
Can't really find it anywhere in the thread.

How did you attach the Emgo shorty? did you have it welded on?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Jan 23, 2013, 20:25:30
Used an exhaust clamp.  You'll also need to cut slits in the end of the muffler to give the clamp something to "clamp" down on.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: StryfeS13 on Jan 24, 2013, 00:14:46
We need a vid of that new exhaust!

I'm trying to decide on one for my GN400. I want it to sound like a 400 or 450f(dirt bike) if even possible..
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: reesea17 on Jan 24, 2013, 13:43:05
Used an exhaust clamp.  You'll also need to cut slits in the end of the muffler to give the clamp something to "clamp" down on.

Can you post a closer picture of this for reference?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Jan 24, 2013, 21:18:42
Here you go:
(http://img.photobucket.com/albums/v76/undertheradar/695C5DCF-F8DE-4D3B-9FF2-ECE9F20EED7B-10903-00001834054104DB.jpg)

and here's a short vid of it:
http://www.youtube.com/watch?v=xrozZOk9wsY


Got my helmet today.  :)  Torc Super flake with Biltwell smoked shield.
(http://img.photobucket.com/albums/v76/undertheradar/09C4EF21-013F-451F-962E-E8FA76F9B3D6-10903-00001833FE5558B9.jpg)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: StryfeS13 on Jan 24, 2013, 23:09:01
Weird question but how tall are you? I keep sitting on my bike (it's just a frame haha) and I keep worrying I'm too big for it lol!

I'm 6'3"...same build as you. Does it feel too small?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Jan 25, 2013, 01:25:37
lol, I'm only 5'7 so it fits me perfectly.  :D
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: NBraun on Jan 25, 2013, 02:01:39
Sweet bike dude! And that helmet is super awesome! ;D
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: MJPriceisright on Jan 25, 2013, 11:34:02
haha that helmet is so tight. 
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: gk45011 on Jan 25, 2013, 12:01:08
let me know what you think of that helmet and how low profile it is. I am looking at the black/grey/white union jack one to add to the collection.

GK
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: StryfeS13 on Jan 28, 2013, 17:52:11
Where did you get your threadserts for the seat? Do you think just drilling holes and welding bolts onto it as a stud would work the same way?

And do you have any good pictures of how you mounted the electronics?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Jan 29, 2013, 04:12:40
I got mine from McMaster Carr locally, but they're just 1/4-20 aluminum.  You can buy a cheap tool and a selection of inserts from harbor Freight.   I was just out of that size from my kit.   Welding would work, but this was far easier for me and allowed everything to sit flush.  The pic I [osted a few pages back is the best I have.   I basically laid everything out off the bike, traced each compontent, then cut out a piece of velcro to fit.  If the part had bolt holes (like the rectifier) then I bolted it on.  Light stuff like the flasher relay is just held on by the heavy duty velcro.  All the wires are taped and ziptied so nothing is going anywhere.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: StryfeS13 on Jan 30, 2013, 22:45:17
Besides your CDI and battery, what else is mounted under your seat?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Jan 31, 2013, 04:40:47
Everything that came stock on the bike:  rectifier, cdi, flasher and battery.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Feb 07, 2013, 23:29:57
Some of you CA guys will know what a relief this is, but I finally got my plate/title today.  Only took 3 trips to the DMV and one to the CHP to get it done. 

(http://img.photobucket.com/albums/v76/undertheradar/C99777E8-15CA-47D5-B7AE-9FB52338AD1F-1866-000002F218D11B85_zps251d89a5.jpg)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: gheorghe on Feb 08, 2013, 12:00:30
Very nice scoot man, I really love the seat and the overall proportions. Good job! So did you stick to your initial  <$1000 budget?  ;)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Feb 08, 2013, 16:51:01
Yeah man...definitely under a grand.  :)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: mikewerx on Feb 09, 2013, 00:43:11
The rear is a Firestone ANS, the front is a Dunlop K70.   I suppose they're both like a on/off road tire.   This will only see pavement....I went solely for the looks.  :D
(http://img.photobucket.com/albums/v76/undertheradar/F9528A0C-1B8A-439F-967E-75E84ABC57D1-4726-00000984A1E99E34.jpg)

So where did you get those tires?  Liking them since you've been riding them for a while?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Feb 09, 2013, 03:18:36
Front is from motorcyclesuperstore, rear is from DCC.  From my limited experience, they ride really nice.  Fairly grippy, and plenty smooth too. Not something you want to be throwing into the curves at WOT, but fine for daily cruising.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: StryfeS13 on Feb 11, 2013, 22:52:52
Hey, on your GN, there should be 2 plugs coming from your magneto and a couple wires...and then there's a random red or pink wire with a female connector on it, where does it plug in on your bike?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Feb 12, 2013, 02:12:10
Not sure.   I'd love to help you, but my harness is all loomed and taped up.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: StryfeS13 on Feb 18, 2013, 19:07:36
So I've been trying and trying to get a VM36 working on my GN400 and I'm all the way down to a 15 pilot and it's still too rich. I gave up haha.

With your stock carburetor, and a pod filter/open exhaust, what jetting are you using? My stock carburetor jetting is causing my bike to shoot flames out the exhaust and all kind of cool shit. I want to get my jetting right lol
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Feb 20, 2013, 15:12:19
Stock pilot jet, but I went up from the 132.5 stock main to a 142.  It runs fantastic, but it does pop quite a bit on deceleration, with the occasional nice blue flame too.  Plug looks good...so its mostly the tiny muffler.  If I put the stock can back on its really quiet with no popping/flames.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: StryfeS13 on Feb 20, 2013, 20:52:31
With your stock 132.5 did your bike pop and backfire like crazy when revving it? That's what mine is doing right now with a pod filter and open exhaust. I'm thinking I need a bigger main jet, or to put a washer or two under the needle.

EDIT: I just tried a 142 main and it is still backfiring and throwing fireballs out the exhaust lol
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Feb 23, 2013, 00:10:57
Yes, it still does it.  :D  I'm going to start upping the pilot a little to see if I can reduce it some, but I'm not too concerned with it.  As of right now my plug looks good and the bike pulls hard through all the gears.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Mar 04, 2013, 04:00:36
Bumping my thread since I just got some cool shots done by a buddy of mine.

(http://farm9.staticflickr.com/8104/8522691275_53589983cd_c.jpg)


(http://farm9.staticflickr.com/8529/8522687687_65f2342ca0_o.jpg)


(http://farm9.staticflickr.com/8094/8522687515_e43b95c5a5_o.jpg)

(http://farm9.staticflickr.com/8235/8522687809_0e930185c3_o.jpg)

(http://farm9.staticflickr.com/8517/8523803514_df13575bd0_o.jpg)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: MJPriceisright on Mar 04, 2013, 09:10:31
very cool pics man, bike looks great.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Mar 05, 2013, 00:35:23
Thanks man.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: M.B Co on Mar 13, 2013, 13:46:32
Shots turned out great. Nice build!
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: ajeevisser on Mar 28, 2013, 05:34:15
Great build.! Love that wild style.
Building a GN400 myself right now.
I've got a Dunlop K70 and want to order a Firestone ANS.
But what size fits?
Thought it was a 4.5x16 but the tirelabel on the picture you posted  says 5.00x16.
What should I order?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Mar 29, 2013, 21:50:38
Rear is a 5.0-16.  It fits fine.   The K-70 on the front is a 4.0-18.  I'm pretty sure a Firestone ANS 4.5-18 will fit too, just havent had a chance to buy one and test it out.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Mar 29, 2013, 21:51:30
(http://img.photobucket.com/albums/v76/undertheradar/New/C8936785-B91C-4595-8A24-4C2BD8BB2F64-5745-00000280403EF82A_zpsd0326761.jpg)
Title: Back at it....this time with an 81 Suzuki GN400.
Post by: bravecafe on Mar 30, 2013, 01:07:20
Sweet, we are building one as well. Looks like the gn400 secret is out! :)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: Jay Chrisman on Mar 30, 2013, 11:05:36
My son and I are doing a gn 400 and was wondering about a sealed battery from ebay with more amp hrs ? would this power the lights better?  thanks Jay
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Mar 30, 2013, 21:15:40
From wyhat I understand, the lights get their power direct from the coil, so I don't think a bigger battery would do much.  My headlight dims a bit at idle, but is nice and bright while riding.  My battery is  1.2 amps. Taillight has a 6v LED bulb in it and is super bright.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: ajeevisser on Apr 04, 2013, 11:12:11
Does anybody know if the forks of the Holiday Customs GN400 are lowered internally?
It looks like they are just lowerderd in the steering stem.
My fork seals are leaking, so I've got to rebuild mine anyway.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Apr 08, 2013, 00:21:30
Almost positive they're lowered internally.  I tried just sliding them up in the trees and the front end was just way too high.  Internal is the way to go.   I took 3" out of mine.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: ajeevisser on Apr 08, 2013, 07:40:34
There are two little  holes covered from the spacers then.
Think they are some sort of oil channels.
Any problems with that?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Apr 08, 2013, 16:23:29
Nope.  They work great.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: Dec79 on Apr 08, 2013, 17:32:51
Love it  8)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: reesea17 on Apr 09, 2013, 12:12:19
Does anybody know if the forks of the Holiday Customs GN400 are lowered internally?
It looks like they are just lowerderd in the steering stem.
My fork seals are leaking, so I've got to rebuild mine anyway.

Almost positive they're lowered internally.  I tried just sliding them up in the trees and the front end was just way too high.  Internal is the way to go.   I took 3" out of mine.


I actually emailed Jared a little while ago asking how he lowered the forks on the CB450 projects he'd done and all he said is that he cut the springs in order to shorten them.  Not sure if thats 100% the only thing he did but it seems an easier route then having the fork tubes themselves machined and shortened down.  I think I might take the spring cutting option to my forks and see what happens..
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Apr 10, 2013, 03:22:05
If he cut the springs, then he likely added spacers, which is what actually causes the lowering effect.  That's what I did on this bike.  No need to do anything to the tubes themselves.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: ajeevisser on Apr 11, 2013, 11:23:47
I made some 2" spacers. Think that's the right way to go.
Cierrecart used 3" spacers and his fork is very low.
Is it right I have to cut the springs 2" too?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: tafspeed on Apr 14, 2013, 14:30:34
Cut and shaped a Walmart workout may today.  Glued 3 layers on, cut to shape then used a flap disc to shape it a bit.  Should be good enough.  I plan to have it professionally upholstered.  Looking at black leather/vinyl with red stitching in either tuck n roll or diamond pattern.

(http://img.photobucket.com/albums/v76/undertheradar/B929CF20-D2EC-49FC-87E0-FF21AEBAF33D-3023-00000578E0707983.jpg)

What glue did you use to stick the layers together and to glue it on the base?

grtz
Manu
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Apr 15, 2013, 01:40:27
I made some 2" spacers. Think that's the right way to go.
Cierrecart used 3" spacers and his fork is very low.
Is it right I have to cut the springs 2" too?
I made some 2" spacers. Think that's the right way to go.
Cierrecart used 3" spacers and his fork is very low.
Is it right I have to cut the springs 2" too?
I made some 2" spacers. Think that's the right way to go.
Cierrecart used 3" spacers and his fork is very low.
Is it right I have to cut the springs 2" too?

I still have decent travel and plenty of clearance.  You can cut the spring the same length as the spacers you added, or you can do like me and leave them a half inch longer to add some preload when you put the caps back on.


As for the glue, I used good old Super 77 spray adhesive in the can.  ;)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: ajeevisser on Apr 16, 2013, 04:23:14
If I use a 2" spacer and cut the spring 1.1/2" , how much fork oil do i have to add?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: johngchrist on Apr 21, 2013, 22:24:46
Love what you have done with your bike. I just started in on my 400 and was wondering what you did with the speedometer throttle and brake cable.  If you got new ones what lengths did you get and how much did you end up spending?  I may just run to the salvage yard and try and find something. Just curious to see what route you took.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Apr 23, 2013, 17:22:54
My cables are all stock except for the braided brake hose.   Can't remember the length, I just measured from the caliper up to the new bars and used that. 
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on May 30, 2013, 22:14:05
Swapped out the pipe for this raw steel reverse cone.  Also added mx pegs and some chopped down bmx pegs for passenger pegs.
(http://img.photobucket.com/albums/v76/undertheradar/New/null_zpsa04bffe0.jpg)

(http://img.photobucket.com/albums/v76/undertheradar/New/null_zps1e08e14c.jpg)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: reesea17 on Jun 03, 2013, 23:00:53
Swapped out the pipe for this raw steel reverse cone.  Also added mx pegs and some chopped down bmx pegs for passenger pegs.

Absolutely love your idea of using the mx pegs. Have been planning to replace mine with something non stock and couldn't really find anything I liked until now. 
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Jun 14, 2013, 04:36:25
Thanks man.  These required some slight shaving of the sides, but they fit great.  New pic from a 150 mile ride last weekend,  Bike ran freaking great.
(http://img.photobucket.com/albums/v76/undertheradar/New/null_zps81b9a48b.jpg) (http://smg.photobucket.com/user/undertheradar/media/New/null_zps81b9a48b.jpg.html)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: M.B Co on Jun 20, 2013, 17:57:05
Muffler discolor that much already?........i like it 8)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Jun 22, 2013, 16:11:40
Yeah....that was after about a 75 mile run.  I like the look.  :D

Make sure you guys check Bikeexif next week too.  ;)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: M.B Co on Jun 24, 2013, 10:44:14
Saw it last night. Congrats! I bet that's a great feeling.

My build will be sub $750 since the bike was freeeeeeee
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: johngchrist on Jul 17, 2013, 20:22:14
I just got the 4.5-18 ANS and it fits with out a problem. Stoked on the look, deff worth the money.


Rear is a 5.0-16.  It fits fine.   The K-70 on the front is a 4.0-18.  I'm pretty sure a Firestone ANS 4.5-18 will fit too, just havent had a chance to buy one and test it out.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: M.B Co on Jul 18, 2013, 18:33:19
If ya don't mind...I'd like to use your seat design and pattern.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: MickyC on Jul 22, 2013, 00:38:43
this bike came out sweet mate well done seat / tank combo looks great.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: ILoveThumpers on Aug 12, 2013, 15:05:25
Loving this build. Don't know how I missed it! MisterOddJob's build has disappeared from the site; he had some really great fabrication shots and details on his build that I wish hadn't gone away.

I'm doing something similar with my GN400. It's an 80, with the gold/aluminum cast wheels. Rather than hunt down spoked wheels I'm going to use the wheels as a platform for the whole build. It's gonna be rad!

Great work; would love to see a video of it being ridden!

-Deek
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Aug 15, 2013, 04:17:16
If ya don't mind...I'd like to use your seat design and pattern.

Sure thing man.  :)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Aug 15, 2013, 04:20:30
Sure thing man.  :)

Here's one on a local canyon:
http://www.youtube.com/watch?v=FHY78s3ZMG4

Here's one from my very first ride:
http://www.youtube.com/watch?v=HJ8TCL5GPlk
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: Drey6 on Sep 09, 2013, 18:13:15
Was that first video sped up to fit it in ? Looks pretty fast on those curves!
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: jordanarmstrong on Oct 05, 2013, 17:33:08
Hey Chris,
 im working on my own GN400 project but im running into CDI problems. I have 3 of them, all fried :(. i have a cdi and ignition coil on the way from a honda ch250 (Andy from the GN400 forum talked me into it) Im hoping that solves my no spark issue. Your bike has been a big inspiration for me through my build. my last bike was a cb750 and also being 5'7" it was way too big for me. this bike is the perfect size.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: jordanarmstrong on Oct 07, 2013, 16:45:43
Tank decals and header pipe baffle:
(http://img.photobucket.com/albums/v76/undertheradar/9F2B7FD2-34C2-4FF7-8635-96A10524B975-1082-000002EB698D16E1.jpg)

(http://img.photobucket.com/albums/v76/undertheradar/31B21E40-A52C-4FB5-B258-9611EDA55824-1082-000002EB6C7496C9.jpg)
Where did you get the baffle and what size is it? (sorry if you have already answered this question, i looked but i couldnt find it if you had) I have been looking at a few but im not sure if an 8" would be too long for the area we have to work with. let me know please. Thanks Sir.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: Doogie on Oct 08, 2013, 22:28:47
Dude, I just read this whole thread. Awesome build. Very clean and classy.

Very inspiring. Great work.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: UNCOILED on Oct 09, 2013, 14:15:36

(http://farm9.staticflickr.com/8235/8522687809_0e930185c3_o.jpg)

Can you show a close up of wrench on the tank? How did you do that? I'm assuming its painted on or an indention of some sort?

Bike looks amazing by the way.
Title: Back at it....this time with an 81 Suzuki GN400.
Post by: Drey6 on Oct 10, 2013, 00:32:48

(http://farm9.staticflickr.com/8235/8522687809_0e930185c3_o.jpg)

Can you show a close up of wrench on the tank? How did you do that? I'm assuming its painted on or an indention of some sort?

Bike looks amazing by the way.

I think the wrench is a stamp added to the picture from the dude that took the photos, not sure that's actually on the tank. But I could be wrong.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Oct 10, 2013, 20:33:21
Hey guys, the wrench is just a Biltwell sticker I threw on there.

Unfortunately I can't help you on the cdi front Jordan, but the baffle is 4" long made for 1 1/2 pipes.  Got it off ebay, and 4" is the max you can go otherwise it will hit that first bend in the header pipe.  Still haven't got around to getting a Firestone for the front.
Title: Back at it....this time with an 81 Suzuki GN400.
Post by: Drey6 on Oct 10, 2013, 20:44:58
On the new LED turn signals  did you use a flasher relay to keep them working properly ? Or something else?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Oct 10, 2013, 20:48:34
On the new LED turn signals  did you use a flasher relay to keep them working properly ? Or something else?

They're not LED's, standard lights with 6v bulbs thrown in.
Title: Back at it....this time with an 81 Suzuki GN400.
Post by: Drey6 on Oct 10, 2013, 20:49:08
Sneaky dog, they look slick. Couldn't even tell.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: jordanarmstrong on Oct 10, 2013, 22:12:52
Cool, thanks for the info on the baffle! I got too excited and didnt read the name of the poster, it was someone else (photos on the gn400 yahoo group) that had the firestone front tire. It does look slick but i just wanted to see it on a spoke rim.
thanks dude.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: jordanarmstrong on Oct 28, 2013, 22:35:49
Hey man, I had a quick question. Iv'e seen arguments for both sides, Have you had any handling issues with the front end without having any fork supports? I know a lot of people who go without a front fender go with a fork support.
Let me know what you think.
Thanks!
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: cierrecart on Oct 28, 2013, 23:18:41
I haven't had any issues with my setup, but I don't push my bike too hard either.  There has been a few times where I have been pushing into a curve or something and I can feel it flex a little, but nothing scary or anything.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: whizzard on Jun 25, 2014, 00:15:43
Super nice GN250, who knew that they could look so good! :o

I also went through the whoel thread, but was wondering if you can/would add a summary post to the first page with a list of the mods that you did and parts that you use. This woudl be mighty useful and could be referenced as what to start with for others about to embark on similar customs.

Thank you again for all the time and effort.

-Whiz
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: jordanarmstrong on Jun 25, 2014, 09:45:00
You sure you read it whizz?
even the title tells you its a 400 not a 250...
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: Drey6 on Jul 01, 2014, 11:12:25

You sure you read it whizz?
even the title tells you its a 400 not a 250...

Haha exactly.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: INDYRACER44 on Jul 11, 2014, 01:21:55
Just picked up a GN400 for my first bike... love the stance that you gave this bike. How many inches did you lower the front total? and what size rear shocks did you use? Also is it necessary to raise the back if I just lower the forks about 4.5 inches?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: Big Rich on Jul 11, 2014, 01:36:49
I hope I read that wrong Indy. Lower the forks 4.5"?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: Drey6 on Jul 11, 2014, 02:20:33

Just picked up a GN400 for my first bike... love the stance that you gave this bike. How many inches did you lower the front total? and what size rear shocks did you use? Also is it necessary to raise the back if I just lower the forks about 4.5 inches?
(http://img.tapatalk.com/d/14/07/11/gy2uvevu.jpg)(http://img.tapatalk.com/d/14/07/11/e6yquzu7.jpg)
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: INDYRACER44 on Jul 11, 2014, 10:17:36
I hope I read that wrong Indy. Lower the forks 4.5"?

Well he lowered the forks internally about 3.5 inches and raised them couple of inches for clip on handlebars... I just was wondering if I kept the stock shock absorbers on the GN400 how much could I raise the forks?? Im 6'0 tall so if I raised the front and back just like he did would the bike be too small? I like the stance for this bike and want to replicate it.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: CBray4 on Jan 22, 2015, 23:10:18
I know it's been forever since anyone has posted on this but I was wondering how you painted your header and muffler. I have the same bike and same muffler but mine is chrome and I like the look of the flat black. Did you use the same paint you used for the wheels and frame?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: Tijmen on Jan 23, 2015, 11:06:36
I know it's been forever since anyone has posted on this but I was wondering how you painted your header and muffler. I have the same bike and same muffler but mine is chrome and I like the look of the flat black. Did you use the same paint you used for the wheels and frame?
This should work:

http://www.vhtpaint.com/products/flameproof/

Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: Madmannc on Jan 23, 2015, 17:35:05
What made you change the emgo muffler with the megaphone one?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: sivilized on Jan 25, 2015, 19:47:11
This really came out great. Congrats! Love the stance.
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: Madmannc on May 29, 2015, 22:33:38
Hey there, would love to get an update on how the bike is holding up; the engine paint, the seat, etc...how is it?
Title: Re: Back at it....this time with an 81 Suzuki GN400.
Post by: Drey6 on May 30, 2015, 01:34:07

Hey there, would love to get an update on how the bike is holding up; the engine paint, the seat, etc...how is it?
+1