DO THE TON

Blood Sweat Tears and Grease => Projects => Specials => Topic started by: misteroddjob on Apr 03, 2012, 04:39:48

Title: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: misteroddjob on Apr 03, 2012, 04:39:48
Nothing here
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: guernz on Apr 03, 2012, 05:50:27
Thats going to be a sharp. I love that swingarm that you are using.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: JustinLonghorn on Apr 03, 2012, 12:57:50
I'm on board.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: Maritime on Apr 03, 2012, 13:55:02
Nice work so far, I am on board.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: Maritime on Apr 04, 2012, 08:28:38
Cool the 5 reds, gear indicators?  The others are obvious signals, high beam and neutral.  Very slick.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: teabowl13 on Apr 04, 2012, 12:28:40
Yeah...
This whole thing is REALLY slick! I'm drooling. Waiting for more!
 :o
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: teabowl13 on Apr 04, 2012, 23:54:25
....
I started the build thread after I was far enough along that I was confident that it would be finished.

Yes, Yes...
If you click on my own build thread link, you'll see the many long months since I've been able to post anything new... namely because I have been counting on my "FRIEND" to do the majority of the build... Hmphh...
Thus I am on here looking at cool pics of other cool bikes that I can't ride....
Cheers!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: peteGS on Apr 05, 2012, 09:20:04
Mate I love your work, this is gonna be awesome :D


I've got a thing for Zuks and scramblers... so your build is right up my alley...
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: peteGS on Apr 05, 2012, 17:57:18
Thanks. Your thread is another one that I've followed before posting my own for obvious reasons.
But also because my first streetbike was a GS450T.
I also own a DR350 set up as an adventure bike.
So I have a thing for Zuks as well.

Nice one! I would've liked a T to scramble to be honest, much better tyre selection and wire wheels... but you can only work with what you have and T's are extremely rare over here.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: teabowl13 on Apr 05, 2012, 19:22:29
...
I started second guessing if it was even worthwhile to finish my build when I saw what people were doing with Savages

HEY MAN!
Thanks for chiming in; I'm glad you saw my build thread; Jay swears we'll be done in a month! I'm scratching my head.
I've seen that bike that you posted up; in fact there's a huge build thread all about it on the Savage Forum. Taht thing went through a hundred different versions before it got to be what you saw, and he has every bit of it documented. It's really quite amazing; a total frankenstein. I'd still like to try the Mono-shock on mine; maybe some day, but this year I just want to ride that damned thing! I found my Savage for just $250; so there's no reason you can't find one to work on when your scrambler is done...

You may have seen these, but here's that monster Savage build:
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1264727267/0 (http://suzukisavage.com/cgi-bin/YaBB.pl?num=1264727267/0)

There's also another guy who started a Cool Savage Scrambler, but sadly had to abandon it. I think he sold it:
 http://suzukisavage.com/cgi-bin/YaBB.pl?num=1300168343/0 (http://suzukisavage.com/cgi-bin/YaBB.pl?num=1300168343/0)

CHEERS!!

Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: brandEn on Apr 06, 2012, 00:42:07
subscribed. Lookin sweet!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: peteGS on Apr 09, 2012, 09:19:35
Man I like your attention to detail... this is gonna come together nicely :)
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: Swagger on Apr 09, 2012, 20:44:06
Mr.Job....I gotta say man, fantastic work all around! Timing and all.....I've been contemplating an 'Inappropriately Offroad' event for the Fall, basically taking any crapwagon bike you want, strip off all the garbage, spoon on some dirt tires and go thrash.
I fully anticipate seeing someone offroad a GL11100 (don't ask) but your bike is far more developed that what I'm proposing. My idea is more of a Ghettocross or Stupermoto type of thing...wish I'd coined those terms, makes me giggle every time I say it!

But anyway, lovely work I'll be following!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: Swagger on Apr 10, 2012, 03:06:14
Well, a dirty version anyway. In fact the rule is no actual dirtbikes allowed.
All bikes will be welcome on the run but I plan to poke fun at anyone bringing a real dirtbike or dual sport. Crapwagons for the win!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: Swagger on Apr 10, 2012, 14:07:55
Special is one way to put it!
Back when I was dirt biking every weekend (I'm now dating myself) there were still guys careening thru the underbrush on stripped down Triumphs and BSAs. Dad and I rode with this kat named Nandor (the Great!), this crazy Hungarian guy about 5'2" of insaninty. He rode a Norton Comando with and Earle's front end and Fox air shocks. It was the goofiest and to my 14 year old mind the most terrifying and inspiring bike I'd seen to date. If it weighed less that 500lb I'd be stunned. You could in all truth hear it 3 miles away....just bonkers.

I'm hoping for similar insanity.
Oh there will be video.....Oh yes.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: massey65 on Apr 10, 2012, 22:32:52
Is that GN400 running a 6 volt system or a 12 volt system? If its 12 how did you convert it? And what kind of gas tank is that? That bike looks nice.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: massey65 on Apr 11, 2012, 14:07:23
Thanks for the info Here is a pic of my Suzuki I am currently rebuilding the front forks. I am new to motorcycles so I dont know alot about them. I would like to switch to a bigger rim on the front. DO you what rim off of what bike would fit the front of my suzuki so that I could put a bigger tire on the front like maybe a 110/90-18 tire instead of the 90/90-18 thats on it now? Your bike looks awesome. I cant wait to see how it turns out. Mine is coming along slowly.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: massey65 on Apr 11, 2012, 17:03:03
OK Cool I hadnt thought about switching to spoked rims, I like my mag wheels. So your hoping to build a cafe racer correct? I would like to go cafe with my bike. Im wondering how that gas tank is going to look when evrything is done. I was thinking of a manx style gas tank, but they are so expensive. If your clarke tank looks good maybe I will go that way. It looks like a good tank I just dont know if its the look I want. I have been looking at so many different tanks and seats its hard to decide what to do. Building a bobber would be easier I think. I could just build a rat bike. I dont know what to do yet but Im getting some good ideas from your build. keep up the good work.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: massey65 on Apr 11, 2012, 18:42:41
I agree with what your saying about the bobber not being very practical for riding, thats why I would like to go cafe because I like to ride for long periods of time and the cafe style also suits my riding style. I do like that yamaha tank I think that maybe Ill check out e-bay and see if I cann find one of those.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: JustinLonghorn on Apr 18, 2012, 12:08:26
Looking good, man.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: Swagger on Apr 18, 2012, 12:55:29
Fun, I like how this one is developing.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: JustinLonghorn on Apr 18, 2012, 13:04:16
Ha, that's pretty rad.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: massey65 on Apr 18, 2012, 13:06:37
So will the tank glow when its full of gas?  I have been riding my GN400, but theres rain today so I cant ride. Bike is looking good. Later.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: Swagger on Apr 18, 2012, 13:33:20
That Motolana swinger is pretty sexy too!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: massey65 on Apr 18, 2012, 16:40:27
I guess your right I hadnt really thought of it as being a fuel gauge. Wow thats neat. 
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: teabowl13 on Apr 18, 2012, 16:40:55
AMAZING... I can't wait!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: Swagger on Apr 18, 2012, 17:07:03
HAHA! That's pretty fantastic, I normally kinda laugh at LEDs on bikes and cars but that's a great idea with some real utility.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: Kozanatos on Apr 19, 2012, 03:42:27
Isn't that why dirtbikes are illegal on the road. Plastic tanks?
Your fab is amazing. Ill have to post up a photo of a truly amazing place for one with your skill.I was at a motorcycle yard today. Endless fork setups, front wheels, discs, swingarms, gas tanks, anything.

Hopefully you have one close by so your creative talent can always be stocked with parts.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: peteGS on Apr 19, 2012, 10:10:14
Man this is gonna be awesome! Love the idea with the LED's for a fuel gauge, smart and cool all rolled into one...


Love the stance too, just perfect for a scrambler style...
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: drøn on Apr 19, 2012, 14:02:39
Nice idea with the tank. It reminded me of how they did it on the old Ducati race bikes.
(http://www.motorsportretro.com/wp-content/uploads/2012/02/ducati-imola-3.jpg)
I would have painted tank and left it as an iluminated sight gauge if it was me though.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: teabowl13 on Apr 19, 2012, 23:21:43
I keep coming back here to drool....
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: massey65 on Apr 19, 2012, 23:29:04
Your bike is looking good. Say do you have a good working rear wheel for that bike? I need one cheap and in good working order. Mine keeps making a knocking noise when I spin it any ideas as to what it could be? I removed the chain and it still keeps knocking when I spin it freely. It just has a really weird sound to it. Anyone have any ideas?
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: Swagger on Apr 19, 2012, 23:36:55
Does your wheel 'knock' at the same point of rotation every time? Pick a spot say the swingarm up near the pivot. Keep your eye on that point and rotate your wheel til it makes the noise, mark it at the swingarm for a visual reference and then check to see if it's happening at that mark.

Bearings are certainly possible
Bad brake shoes out back could certainly do it
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: massey65 on Apr 19, 2012, 23:40:11
It seems to knock at the same point every time. I have just replaced the brake shoes. The bike only has 18000 miles on it. Why would the bearings go bad so soon?
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: marla_do on Apr 20, 2012, 00:37:20
fucking. glowing. tank.

iaminluv
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: peteGS on Apr 20, 2012, 07:55:39
Ok that is just frickin awesome... here I was thinking my 450 was pretty cool with its pipe and my new dash with the Acewell and the fly screen and whatnot... man it ain't nothing compared to your GN!!!


Love those dual lights with the mesh guards and integrated gauges... that is just far too cool for school... awesome stuff! Definitely digging this :D


Quick edit: How long til she's done and on the road? I wanna know what month to nominate her for BOM ;)
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: andycafe on Apr 20, 2012, 07:56:34
Wow nice, very clean and how's your workshop tiles in all, Nice.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: JustinLonghorn on Apr 20, 2012, 09:14:37
This is going to be a fantastic scoot.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: peteGS on Apr 20, 2012, 17:06:05
Thanks for the kind words.
I expect to be done in about 6 weeks maybe 8.

Next week I'll get the engine soda blasted and the last few parts powdercoated and anodized.
The week after that I drop it off to Fuller Hotrods to build a stainless exhaust, figuring they'll have it for a week or two.
I'll be building and sewing the seat while the bike is at Fuller's.
Then finish the wiring and jet the carbs.

No probs at all! Quality work requires quality compliments :D
 
Are you going for a scrambler style high pipe? 2 into 1 or 2 into 2?
 
I saw another Triumph Scrambler in the flesh yesterday and I still love that stacked 2 into 2...
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: marla_do on Apr 20, 2012, 18:09:46
nicest build i've seen in a while. especially like the gauges

what brand tires?
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: teabowl13 on Apr 20, 2012, 18:59:56
Your dual headlights are AMAZING!! I love what you've done with this.
And by the way, after searching high and low... I got the very same turn signals! I really wanted dual filaments, especially in the rear because I will have a fairly small-ish vintage taillight. (I haven't any new pics to post because the bike is two states away in someone else's hands, but progress is being made, and with luck you and I shall be on the road around the same time... WHEEE!!)

Cheers!!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: Swagger on Apr 20, 2012, 21:02:52
Mefo Explorers.....well whadaya know?! I learned of new bitchen tires today! I love this joint (and this bike)
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: teabowl13 on Apr 21, 2012, 11:27:36

I also wanted to be able to use 1157 LED bulbs.
I'm switching out every bulb to an LED to save some amperage draw...

I was hoping to do the same thing, but a quick search on Ebay didn't turn up any 2-filament LED replacement bulbs.
If you found some LED bulbs that fit these signals, I'd kiss your feet for sharing your source... or maybe just owe you a beer.

(http://p1.bikepics.com/2011/12/10/bikepics-2314669-full.jpg)

This is the taillight I am using; it's an old BSA rocket light; there are three bulbs inside. One in the center that is pretty standard, but there are two on the sides where the cones are that are super-small, and screw into mounts that are made  from col springs. The original unit is 6V, like yours, but amazingly, our local Napa had 12V bulbs that FIT! I hooked them up to the battery, and they are quite a bit brighter than I was expecting, but I will be running a teeny-tiny Lithium-ion battery, and although the charging system is set up for 12V, and is fairly modern, it would be nice not to tax it too too much with the extra running lights...

I should have my bike in hand within the month; once Jay finishes the frame welding and paint, he'll re-assemble it and drag it up here for all of the final tweaks... Still not sure how all of the electrical stuff is going to get done... details details....

CHEERS!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: peteGS on Apr 22, 2012, 08:46:43
Definitely a high pipe
And actually 1 into 1. The GN is a thumper.
It will be very similar to this except with a larger reverse megaphone muffler.
(http://farm8.staticflickr.com/7191/7097151449_1792210eed.jpg) (http://www.flickr.com/photos/hallucid8/7097151449/)




Aaah I thought the 250 was a thumper and the 400 a twin... that sort of pipe should be a perfect fit, and reverse megaphone all the way! I almost made the mistake of going for a Dunstall style end cap when I was getting Tranzac to make mine, but called him back as soon as I got home to change my mind and go with the reverse mega... so glad I did!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: teabowl13 on Apr 23, 2012, 09:34:56
What vintage is your tail light?
Is that an aluminum casting?


Honestly, I'm not sure about the taillight; It's from a BSA; late '50s / Early 60's I think. I found it on Ebay; guy selling it wasn't sure what it was, and I didn't find out until after I owned it. I just did a search for "vintage tail lights" and there it was... I've only seen one or two others on there since "BSA Rocket Tailight" is all I know about it.

The casting is aluminum; I bought that separately. It's a generic vintage looking Repro that fits any of the old Lucas style lights from the British bikes. That rocket light just bolted right in like a glove.

Any help on those bulbs would be awesome! Also, let me know if I need a modulator-mc-thing-a-ma-jiggie to run the LED turn signals; I would assume so....

CHEERS!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: teabowl13 on Apr 23, 2012, 16:26:48
I figured as much about the blinker thingie...
Swivel tells me that taillight is probably from a BSA Rocket-3. Got no reason to doubt him!

A quick google search turned up this replacement lens:
http://smmotorco.com/index.php?main_page=product_info&cPath=19&products_id=388 (http://smmotorco.com/index.php?main_page=product_info&cPath=19&products_id=388)
Maybe these guys know what it will really fit...
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: peteGS on Apr 25, 2012, 16:42:16
Awesome! Love that attention to detail!
 
I need to do exactly the same thing and it looks like Suzuki used the same tach drive on both our bikes.
 
I have the block off plate from the later GS1100 that has an electronic tach ready to go in, but I've managed to round off the head of the nut holding it in.
 
I really like you plug there, nice work!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: Swagger on Apr 25, 2012, 19:09:37
...but YOU made it.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: massey65 on Apr 25, 2012, 19:12:40
Hey man your getting alot further than I would have. I can only hope and pray that my GN400 will ever start shaping up like yours and the same gpes for the end result thats coming. Keep up the good work. Later.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: misteroddjob on Apr 25, 2012, 20:12:48
...but YOU made it.
True. And I'm sure mine is lighter so its the racing version...
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: peteGS on Apr 26, 2012, 16:08:32
...but YOU made it.

+1! I didn't intend to denigrate your work on the plug, I think it's great...
 
I love the satisfaction of making something for your bike and seeing it on there knowing noone else has one anything like it...
 
True. And I'm sure mine is lighter so its the racing version...

Yes indeed! I have no doubt :D
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: massey65 on Apr 26, 2012, 18:30:21
Yeah guys I know what you mean its like those things like I wish I had thought of that kinda thing or why didnt I think of that kinda thing. I guess you learn as you go. LATER.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: peteGS on Apr 27, 2012, 18:52:41
No worries, my comment has nothing to do with you denigrating the plug I made.
Without a bike salvage yard nearby to see parts in person, I rely on a lot of internet research.
Somehow it never occurred to me that Suzuki would make one themselves.
And it would have been much easier to research than the other stuff I had to figure out.

Yeah I know what you mean... when I first thought about the Acewell it was bugging me, then one of the other guys on the GSR posted up he plugged it with the later GS1100 one and provided part numbers so that made it easy :)
 
I still reckon your plug is a little classier though, looks well fabricated :D
 
Yeah guys I know what you mean its like those things like I wish I had thought of that kinda thing or why didnt I think of that kinda thing. I guess you learn as you go. LATER.

Yes indeed! At least a lot of stuff you can go back and correct later.
 
My breather catch tank is the perfect example, looked fine with just a breather filter on there but as soon as that filter gets a bit of oil in it, it starts dripping, and at speed those little tiny drips go everywhere... so on with the catch tank and no more drips to mess things up!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: miserygit on Apr 29, 2012, 17:41:35
I'd like to say thanks for the inspiration. Your attention to detail and workmanship is amazing.  ;D

I'm going the opposite way to you - converting a DR400s trailie into a cafe style bike, though that might change as I work my way through the build due to either design ethos or most likely cashflow.

(http://C:\Users\Robert\Pictures\DR PICS\IMG_0053.JPG)

You may recognise the tank. I've also grafted on a GN 400 swing arm (strangely wider than the DR frame) and moved the rear upper shock mount backwards to suit.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: miserygit on Apr 30, 2012, 07:29:53
Yes I used the GN swingarm for aesthetic reasons but after spending a lot of time on the net I realised that the swingarm had other benefits too.

As you mention a wider tyre can be used and despite the fact the GN swingarm is shorter than the DR one, the shock mount is further back. This allows me to use the now beefed-up seat mounting holes as the upper shock mounts, bringing the shocks about 10 degrees from the vertical and I have a greater choice of shocks because of the shortened distance between mounting points.

Overall the aesthetics are improved because the rear axle is closer to the frame and the shock position is similar to an old-school racer set-up.

I'm keeping the front forks from the DR but putting a spacer under the damper rod to reduce their length and travel.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: peteGS on Apr 30, 2012, 10:02:53
That'd be an 80 - 82 GS450E/S tank on there... ;)
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: miserygit on May 01, 2012, 18:19:30
The Suzuki thumper makes a good base for a special.

Have you seen this one? - http://www.ebay.co.uk/itm/ws/eBayISAPI.dll?ViewItem&item=110851687256

 ;D
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: massey65 on May 02, 2012, 19:06:06
that is definitely a nice bike
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: Decken on May 09, 2012, 02:52:57
I would like to say very nice job on the build so far! I just picked up a gn400 myself and was curious if you are going to use a pod filter and run the stock cv carb?
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: massey65 on May 10, 2012, 10:14:47
Is that A newer model mikuni? Is it a direct replacement for the old model or does it need jetted?
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: massey65 on May 10, 2012, 10:23:25
I knew you were gonna say that Damn I would like to run a pod filter but Im not paying to have it jetted.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: guernz on May 10, 2012, 20:44:51
Looking at the parts you build, it looks like you have CNC machine in your garage. Looking at your pics, it looks like you do it all on a drill press.
Very cool.  8) I like it.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: massey65 on May 10, 2012, 20:51:12
I was checking out how some of the parts are made and it actually looked easier than I thought it would be. It makes me think that I can almost do it.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: GrantATX on May 12, 2012, 22:07:21
Any reason why you went with the XS650 front end over say an SR500 front end to match the rear swing arm?

I have a GN400 that I'm getting up and running and I'm looking to do something similar to what you've done...
As I'm also on a budget, I'm just trying to evaluate what will be easiest / best to try and get my hands on.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: filteredsoul on May 15, 2012, 11:52:01
Can you post your jetting specs?
I have a GN400 boardtrack racer special I'm building. I'm still using the zook's CV carb with a larger main jet, air screw tweaked, and a K&N pod. It works pretty well, but I'd really like to get away from the CV. I think the stock carb is a 36mm... any particular reason you went with a 32?

Awesome project by the way!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: MickyC on Jun 18, 2012, 01:12:27
be keen to follow this one. 
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: robm on Jun 30, 2012, 21:44:33
This is a very impressive build! Wow

I have an '81 GN400 that I am working on and can't decide if I'll chop or cafe it - mostly stuck on tank and seat options. Now I know i'll use the same Clarke tank - many thanks!

Two questions:
1. Can anyone tell me the part # for the GS1100 tach block-off plate?
2. When is there going to be another post so I can see what seat I will be using to go with the tank!

Thanks,

Rob
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: robm on Jul 01, 2012, 13:38:09
Thanks for the quick reply. Unfortunately I ordered a black Clarke tank already, but thanks. Thanks for the part # too. I look forward to seeing this build come together. I'm sure your custom seat will give me some direction. Thanks again.
Title: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: JohnnyC on Aug 11, 2012, 19:11:19
I've been following this & just wanted to chime in to say what an awesome looking machine you're building. The pic  of the tree on that car is just awful though. What cars did you lose?
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: peteGS on Aug 12, 2012, 08:32:05
Man that's gotta be heartbreaking! Are either recoverable or too far gone? Really sorry to see that happen... sometimes life just plain sucks! But then usually there's something pretty cool just around the corner :)
Title: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: JohnnyC on Aug 12, 2012, 09:18:42
Sorry to hear it mate, plenty of free(ish) firewood though?
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: peteGS on Aug 12, 2012, 16:45:34
They're both too far gone.
Even if the Sunbeam could be straightened by a bodyman with superhuman abilities, it will be impossible to find all the glass and the VW pickup is twisted, so it will never go down the road straight again.
I'm going to find another VW pickup, but I was planning on selling the Sunbeam anyway.

That's just tragic... there's a guy diagonally opposite us here who has a little Sunbeam of some sort, look like fun little cars...
 
I hope you find your VW and am looking forward to seeing the GN come to life!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: massey65 on Aug 13, 2012, 20:26:27
whats up long time no see. Hows the GN coming along? Damn sorry about your cars and the tree.  I just bought a new bike to go alongside my GN. A 1986 Honda Magna VF700C its a really big difference when compared to my GN. I still ride the GN just not as often.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: blanx77 on Aug 16, 2012, 13:13:04
I just inherited a GN400 from a friend, and will be working to get it up to snuff. I hope you don't mind if I ask you some questions along the way. I have gotten motorcycles and ATVs running in the past, but I have never tackled a build/restoration. Were the XS650 forks necessary to lower the frontend? I'm wondering if the GN stock forks will be too tall for a cafe/scrambler stance, or if a taller rear tire will level the bike out?
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: blanx77 on Aug 17, 2012, 12:15:40
Thank you for getting back to me so quickly. I joined this forum because I saw a photo of your bike online, and I was very impressed with the level of detail. As you can see from my profile picture, I am starting with a pretty raw GN. I'm not 100% on a strict cafe bike. I like the idea of a cafe/scrambler hybrid. I am looking to change the stance of the bike, but not at the expense of safety or functionality.  I like the idea of using the XS650 forks because of their abundance and low cost, and I'm wondering if there are any other forks that would have a similar effect that are plug and play like the XS650's? By the way, I really like those tires, what sizes are they?
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: TwinPlug on Aug 21, 2012, 08:41:58
Great build, love the 'lathe' and the attention to detail.

I'm sorry to see what happened with the cars, was the Sunbeam a Holbay version? - they were called 'Sunbeam Rapier' here in the UK and were available with a Holbay tuned motor, my dad had one back in the day, such a cool little car.

Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: stroker crazy on Aug 21, 2012, 09:45:16
I don't know how I missed this build!

Great idea and great attention to detail.

Crazy


(http://blg.mypicturetown.com/cache/RI5RQ8GNnFdZbmJtj3I0G%25P4MzEhs8xAFEONJO7Um4.3VHCT0myqIhJbX*DjEMB/item.JPG?rot)(http://blg.mypicturetown.com/cache/ie2riIOI.B7l1q%25bKqJLdXQLQ4d%26WuGqJasayOlrA.RN8ZN88V2XYolwTbIja5F/item.JPG?rot)
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: TwinPlug on Aug 22, 2012, 08:33:14
I had an Avenger GLS (Plymouth Cricket??) many years ago, it was a short but fun ownership.

Anyway, I'll stop jacking your thread now!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: hanz94 on Aug 22, 2012, 23:48:40
 (I am going to run the GN motor and won't be using a battery at all, which is one of the reasons I chose it for my base.
The goal is to trim it down to around 275lbs wet.
The GN has a different electrical system than the DR/SP bikes.
The DR/SPs need a battery to run, but the GN has 2 coils, one for the ignition and one for everything else.)

If you aren`t running a battery are you using a capacitor?
I have an 81 GN 400 and have been running without a battery or regulator or rectifier.
Do you have a wiring diagram for your set up.
How do the lights act at idle or higher rpm.

Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: rewindstuff on Aug 28, 2012, 19:36:54
damn. such a good looking build.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: JustinLonghorn on Aug 28, 2012, 23:00:15
Rad!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: massey65 on Aug 30, 2012, 18:14:33
You got any cheap steering dampeners laying around. I hadnt really thought of adding that to my bike until I saw yours My GN has some wobble on the highway and I bet tyat would help hold me steady. So what size sprockets are you going with? I have been thinking of going bigger on mine to get some more  power. Its a 38 rear stock I think, I have a 41 rear sprocket but I think that I have seen a 47 tooth somewhere and I think that quad sport or maybe the lt 230 quad racer sprockets will fit to. That will make it more dirt oriented. I might get a big sprocket for mine and see what happens. I have a 110 chain around here somewhere but there isnt alot of room back there on the swingarm to play around with when I went to the 41 I had to adjust all the way back if I went forward it wasnt right and I got a slightly bigger rear tire so that also adds to the trouble of not having any room to work. I spaced out my brake control arm it was to close to the tire and worried me. Im not gonna put the right size on because this tire is brand new so I will wear it out first then I will put the smaller right size tire on.     GOOD    JOB   ON  THE    BUILD  IT  LOOKS   GOOD.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: jfman on Sep 01, 2012, 00:35:27
Skills, you have them!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: SeekingZero on Sep 01, 2012, 04:31:35
Great job so far.  I can't wait to see this finished.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: SeekingZero on Sep 02, 2012, 01:55:55
I wish I could say the same of mine.  Just dragging my feet right now...though I really want it done.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: juan@crqcycles on Sep 02, 2012, 03:21:04
Beautiful one-of-a-kind build! Nice
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: Maritime on Sep 06, 2012, 09:17:39
That attention to detail puts this build at the top 10% or higher. Most of us hacks would hav just used zip ties or twist ties from the bread bag ;D

Seriously nice work.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: CafeRacer650 on Sep 06, 2012, 11:26:25
Wow, how have I missed this build?!?!  Fantastic!  Signed on with anticipation.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: SeekingZero on Sep 11, 2012, 00:17:53
You might look into the connection on the stator.  If its anything like the DR650, probably not, you could see about altering the connection to get some gain.  See here (http://seekingzero.com/reise/dr650-stator-rewire/).  But saving all that hassle with the LED's should be enough.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: TwinPlug on Sep 11, 2012, 05:39:41
You can rewind those single coil generators yourself, just get some appropriate wire (sligtly thicker for more AMPs) and wind on as much as you can.

Regarding HiD bulbs in old reflectors, the beam pattern would be awful as the light output is hugley different, but you can cannibalise car headlamp units for the projector part of it - I've done this using an Audi A6 headlamp, pulled the reflector mechanism out and transplanted it into a standard headlamp.

It resulted in low beam only, but the low beam from an A6 - so actually much much brighter than the stock unit, even on main beam.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: TwinPlug on Sep 11, 2012, 13:46:37
Thanks, I looked into rewinding it myself a while back and found a place that sells magnet wire online in different gauges.
That'll be a winter project when I won't care if I screw it up.
That's good advice. Where did you find the A6 headlight? And do you think it could be adapted to fit into a 3-1/2" bulb?
If you can solder and wind some string round a broom handle neatly, you can rewind a single coil  :)

A friend runs an older A6 and broke the outer plastic lens on his car, so I had the remnants from him for this exact purpose once he'd got a new lamp unit.

You could try a car body shop for damaged headlamps, they must throw lots of them out when repairing vehicles.

You should be able to fit the HID reflector/lens into any bike headlamp, I had to trim the back of the light unit itself with a dremel type tool and made a rubber gasket to absorb vibration - I didn't take any photo's I'm afraid and the bike is gone now.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: hallin222 on Sep 11, 2012, 14:50:01
The details of this build are amazing.  You're putting 95% of DTT'ers to shame with the quality of work here.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: manolon6 on Sep 11, 2012, 15:08:23
Really great project!!!!
Amazing!!!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: TwinPlug on Sep 11, 2012, 17:29:25
I think that might be within my range of skills.


Seeing what you've done already you'll be doing it yer sleep!
Title: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: SpeedBump on Sep 16, 2012, 14:46:02
Love the build. Don't know how I've missed it thus far.

My real question is, what happen to the truck in the background!?!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: SeekingZero on Sep 16, 2012, 14:50:12
Uh oh.  I still have my exhaust to do too.  Forgot about that...

So, you know, take your time, don't rush it.  ;)  Your exhaust looks great!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: SeekingZero on Sep 16, 2012, 19:21:33
And I still have my electrical to do...
I've got to rush, so I can ride this damn thing to Barber.
I could trailer it, but its not the same.

Sucks that its in AL.  If I still lived in IL I would definitely try to make it.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: timbutterfield on Sep 18, 2012, 19:55:43
Great build I love your commitment to detail.  Exhaust is looking good. I would go for black myself.

Keep up the work, and you'll ride this baby to barber!

You can do it!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: SeekingZero on Sep 22, 2012, 00:26:01
That, sir, is fancy.  It's pieces like that and details like those that make a good bike and great bike.  Many at Barber will be green...
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: miserygit on Sep 22, 2012, 19:38:27
You're still inspiring me!

This website is useful for working out exhaust lengths and diameters.

http://www.mez.co.uk/mezporting/exhaust_length.html

I think there are some other useful calculation tools in the links section at the bottom.

It's looking really good.  :D

Thanks for the inspiration again.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: peteGS on Sep 23, 2012, 07:44:28
Been away from DTT too long and I'm just catching up now... love that exhaust!


Not sure if you've had ceramic coating before or not but I reckon you're gonna love it!


I've got it on my GS450's pipe and it's awesome, don't even know it's running under my ankle...


The only downside is that it's not as tough a finish as chrome, so you need to keep at it with the polish or it will start to show up bits of corrosion etc. and won't look as good as it should.


I just use Mothers aluminium and mag polish and it keeps it looking great even though it's a daily rider :)
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: peteGS on Sep 23, 2012, 16:46:16
Thanks for the welcome back hahahaha...


Mate that pipe's nice, any particular reason you want it in stainless? I would think once it's coated properly as long as you keep it moisture free internally it should last.


Or are you hoping to get a stainless made and not coat it at all?
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: timbutterfield on Sep 23, 2012, 23:53:04
Awesome chain tensioner. I sure do envy your skills and shop, giving you the ability to fab up parts. And that exhaust is looking good. I'm a function over form kinda guy,  which makes me love your bike.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: Big Rich on Sep 24, 2012, 00:37:30
Mister, I have to say I've been following this thread for quite some time now and you are doing some phenomenal work. Kudos to you sir!

And that's a damn shame about that tree incident btw..........
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: CafeRacer650 on Sep 24, 2012, 10:34:55
Thanks.
Function and form are equally important to me.
I went to school for Industrial Design.
Great design does its job efficiently and beautifully.
That's what I hope to achieve with this bike.

I hear that sir.  Looks like you'll make it in time for Barber!  Can't wait to see that bike and be amazed by your handiwork. :)  You must have a nice setup in your shop to be able to do some of the stuff you've been doing.  Great work, as usual!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: CafeRacer650 on Sep 24, 2012, 11:16:24
Wow, but my guess is that since you are a designer, you're pretty well organized.  Great to hear about your progress.  Looking forward to seeing it at the show!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: CafeRacer650 on Sep 24, 2012, 12:33:52
I can't work if its not organized.
Some people can drop a tool in a pile and know exactly where it is.
I drop a tool on an empty workbench and forget where I put it.

I'm the same way.  I can loose a tool in less than 30 seconds if I'm not paying attention.  Drive's me nuts.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: SeekingZero on Sep 24, 2012, 13:14:48
I can't work if its not organized.
Some people can drop a tool in a pile and know exactly where it is.
I drop a tool on an empty workbench and forget where I put it.

+1  ;D
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: JustinLonghorn on Sep 24, 2012, 13:55:33
I spend more time looking for the right tool than I do actually working.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: M.B Co on Sep 24, 2012, 14:56:25
Superior build. Nice job
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: Big Rich on Sep 25, 2012, 20:19:07
Thanks for the kudos.
Was that your GR650 I saw at Barber last year?

If you saw ANY GR650 at Barbers last year, was probably me. I'll be there again this year as well.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: SeekingZero on Oct 01, 2012, 05:04:01
You are really going all out!  This is quite awesome.  Are you going to ride the TAT with it?!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: tron97 on Oct 01, 2012, 09:10:39
Im really diggin the rear rack..

And wicked bag setup. Good work!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: CafeRacer650 on Oct 01, 2012, 10:31:06
She's getting there!  Great work on those bag supports, can you do mine?!? j/k ;)
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: massey65 on Oct 01, 2012, 11:05:49
Your foot wont hit them when kicking it over to start? I always kick my bags when i kick it over to start it.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: SeekingZero on Oct 01, 2012, 15:53:56
Two weeks and counting! Crunch time now.  Crap, if you get done in two weeks then you've beaten me!  It's going to take longer than that for my painting.   :(
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: peteGS on Oct 01, 2012, 16:49:55
Mate that's awesome! Love the rack and saddlebags... have pondered hard/removable bags for mine in place of the throwover Oxford ones I'm using to commute to work and back every day.


I think that removable rack idea is excellent and I may decide to revisit this at some point... I have to use bungee cords to keep the throwovers in place and it gets to be a PITA taking them on and off all the time...
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: timbutterfield on Oct 01, 2012, 20:52:11
Good looking racks! Everytime I check back on your build you've gone and done something amazing! I'm sure you'll get the wiring and seat done in no time!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: peteGS on Oct 02, 2012, 16:37:54
I hear ya. The only thing I bungee anymore is the sleeping bag and tent.
Originally I was going to use throwovers as well, but then I remembered I had a spare pair of Hepco-Becker hoops.
I remembered that the Ortlieb saddlebags had a quick release system that might work with the H-B hoops; did some internet research and the dimensions looked good that they'd play nice together.
It really is a great system with the Ortlieb bags; you literally pull up on the handle and it releases at the same time.
They come off in 3 seconds and go in 5.
Hepco-Becker probably makes a rack for your bike that you bolt on, or buy the bare hoops and do it yourself like I did.


It's certainly food for thought... although no off the shelf rack will work with my pipe which is the biggest problem with it all.


However, pipe benders can be had reasonably cheaply now and I'm not averse to making something from scratch...


Might give it some more thought after I've built my shed and got the little Duc done... before I start thinking about buying my dream bike  8)
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: Big Rich on Oct 02, 2012, 18:13:53
This might interest you Pete:
 http://www.advrider.com/forums/showthread.php?t=577347

Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: peteGS on Oct 03, 2012, 07:39:13
This might interest you Pete:
 http://www.advrider.com/forums/showthread.php?t=577347 (http://www.advrider.com/forums/showthread.php?t=577347)


Indeed Rich... in fact that probably interests me too much  8)


Hmmmm... maybe the GS *isn't* quite 100% complete yet? We shall see...  ???
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: bravecafe on Oct 03, 2012, 20:09:44
WOW!
I have been  AWOL for here for a bit (building and riding). This build has made me remember why I came here in the first place. Top notch and very inspiring. Getting ready to start a GN400 build with my son. Now I can’t wait.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: bravecafe on Oct 04, 2012, 17:32:36
bratt/ tracker/rat
Superbike bars,  Motolana seat, thinking of scrambler style high pipe. Going to try and use the stock tank bare metal, all else black with maybe a little red accent here and there.  One of my first concerns was the front forks. Well you solved that little problem for me:)  xs650 it is ! I'm sure once I get a little further into it I'll be bugging you for specific tips. Really love your attention to detail. You have inspired me to get out the drill and make some pretty swiss cheese. Swagger already has me on a machined dimples kick... :) you should see the petcock extention he made me :)

PS. I would be interested in your "prototype exhaust" if you end up going stainless or not using it?   
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: bravecafe on Oct 04, 2012, 17:46:07
I'll have to look it up, but I thought I saw on here somewhere some tips on taking care of bare metal and patinia..  by Crescent Son ? Like I said been awhile since I have been on. Winter coming and too many builds, I think I'll be here a lot more. I need all the help I can get :)
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: Swagger on Oct 04, 2012, 18:51:23
Jerry? Funny who you run into!
Didn't know you were here mate....
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: bravecafe on Oct 04, 2012, 19:02:56
That's how I meet all you rocker fellas in the first place Bill Beebe (I think)  told me about the Portland  club. Funny thing is meeting some of the rockers then realizing who they were in here. You were ez :) had been bsing with Graham for months before I realized he was Swap Meet  and had helped me a bit in the past. I guess a small world!  Def going to have to find some more pieces for you to dimple in the near future. :)
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: two-smoker on Oct 07, 2012, 12:48:47
I just read this thread from start to finish... I'm surprised I haven't run across it before! I must say, stellar work, and I always knew there was something worth finding under all that ugly... Looking forward to seeing the end result- I like what I see so far!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: CafeRacer650 on Oct 15, 2012, 15:55:31
I thought you'd enjoy these shots...

(https://lh5.googleusercontent.com/-buLOPYWBI1g/UHxbp8Yth1I/AAAAAAAAAoo/5zJcjazTQLo/s640/SAM_0172.JPG)

(https://lh4.googleusercontent.com/-sYyrUm2JCTQ/UHxbvwwMrCI/AAAAAAAAAow/TGyjNmP_hSM/s640/SAM_0165.jpg)

 :D
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: TommyRocker on Oct 15, 2012, 21:56:46
I really dig the removable mount setup.  I might "borrow" some ideas from it. 
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: massey65 on Oct 17, 2012, 22:41:51
Where is that museum located?
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: massey65 on Oct 19, 2012, 23:50:08
I would like to see it someday. How is the bike coming along?
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: acidface606 on Oct 28, 2012, 21:49:17
Hey, I've been reading up about your build, so I had to join in on the zuki talk. I just recently got a bobbed out and hard strutted 81 gn400 for $450. The guy couldn't start it when I went to get it but I  fell in love when I sat on it. Got it home and started digging in, first thing I did was tried to hear it run..the guy cut half of the exhaust out and put a pod filter on it and I guess that fucked with the airflow. When I got it started finally, it was idling at 6-8 grand and was loud as fuck! I'm new to bikes, I had a 83 cb550 but it needed work and just ended up selling it. But I do NOT want to get rid of this bike. Im asking for advice/help.. I really don't know where to begin..please help!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: juan@crqcycles on Nov 15, 2012, 22:04:08
Hey! Is the bike already finished? Show us some pics!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: hanz94 on Nov 22, 2012, 23:17:17
How did the sparx capacitor work?...
Im friends with hugh's handbuilt and build all of my bikes with them. He has a regulator/rectifier and capacitor combination he uses on his PMA conversion kits and it takes the xs650's single unit and seperates the charging system like our gn400's. And i can get him to help with the configuration, but i'm curious if your approach has successfully worked before i start head over heels. And thanks a ton for the descriptive write up you gave on the 6v to 12v conversion theory.
-hanz
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: peteGS on Nov 25, 2012, 15:40:06
Mate that's awesome, very neat!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: juan@crqcycles on Nov 26, 2012, 02:29:07
Nice to see things going again!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: cierrecart on Nov 26, 2012, 20:33:54
Killer job!

I'm building my own GN400 right now and this thread has been a major inspiration.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: rewindstuff on Nov 27, 2012, 12:36:02
Bauhaus?
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: cierrecart on Nov 28, 2012, 04:47:52
Where's your build thread?

http://www.dotheton.com/forum/index.php?topic=43635.new#new
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: skillz on Dec 02, 2012, 17:00:39
Really like this build great job so far! I have been looking to build a similar bike but will definitely be on a tight budget.  I know your running an xs650 forks, and it sounds like it was a straight swap into the gn400 trees.  Do u know if the swing arm is a straight swap as well? 

I basically want to swap in a xs650 front end with 5 spoke alloy wheel and the same for the swing arm assembly. Do happen to know is this is possible?
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: skillz on Dec 03, 2012, 23:33:44
Thanks for the quick reply, guess ill look for another option.  I cant stand the stock alloy wheels. It seem pretty hard to find stock hubs wheels for wire wheels.  This might be stupid question but do u happen to know if any other suzuki models that came with wire wheels can bolt right up to the gn without modification?
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: skillz on Dec 06, 2012, 02:44:06
Interesting! Thanks for the info, can't wait to see your finished product.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: filteredsoul on Dec 07, 2012, 15:37:07
In fact, as far as wire wheels go... some GN400 models came stock with spoked wheels. I don't remember the model designation, but as far as I know, there is a GN400, a GN400T, and a GN400X. I just did a quick ebay check and if you search for "gn400 wheels" you'll find front and rear complete spoked wheels.

Honestly not trying to hijack this thread, but  I have an '81 GN400T that had the cast wheels, but ditched them for 21" motocross hoops for my current project bike...
Just in case anyone is interested in the "build thread" -it's just a little blog, nothing fancy. GN400 kustomizers UNITE!
http://kustomgn400.blogspot.com/ (http://kustomgn400.blogspot.com/)
Title: Review of Sidewinder Sprockets Thread Posted
Post by: misteroddjob on Dec 08, 2012, 11:17:38
I mentioned earlier that I had a negative experience with Sidewinder Sprockets and that I would post a detailed review of this company. Sidewinder is the main reason I gave up on finishing my bike for Barber Vintage weekend, because without the sprockets they promised to deliver it wasn't going anywhere under its own power anyway.

Below is my in-depth write-up about this company; the most dishonest company I have ever encountered:
WARNING: Sidewinder Sprockets - False Claims of Made in America (http://www.dotheton.com/forum/index.php?topic=44177)
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: filteredsoul on Dec 08, 2012, 11:53:17
Bummer about Sidewinder railroading your project. I also had a hard time finding ANYONE to make a custom front sprocket. The only advice I have is to call a company called "Rebel Gears" in Tennessee. I was able to buy a 18 tooth front sprocket (made by PBI) from them. I believe they have 1 left. I almost bought both just to have them, but I would bet it's still there as no one is buying custom sprockets for the GN except you and me. I don't know if 18 will work for you, but that's one of the only options I know of... the other would be to "make" your own. Tractor Supply has various loose sprockets available and one guy on the Yahoo Group "GN400" machined the teeth off a stock front sprocket and machined the inside of the Tractor Supply gear to match and had a welder combine them. They are hardened so the job was tough, but it can be done. Also try looking up motorcycle drag race sprocket companies. I forget the name, but if you google "offset motorcycle drag race sprockets" you may find the company I found once... they make offset countershaft sprockets for using wider rear tires for your drag bike. If anyone would know about hardened/heat treated sprockets (and modifying them) it would be those guys.
Hope this helps a little bit. -and thanks for looking out for the motorcycle community and posting the warning (very well done by the way...) about Sidewinder.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: filteredsoul on Dec 10, 2012, 11:34:10
Definitely let me know what they say. It's not very often that I can actually help someone out!

I remember asking them who in the USA actually makes front sprockets and they didn't know. How is that possible? How hard could it be? Laser/Waterjet cut them out of steel, do a little finish machining, heat treat/harden. Doesn't seem like it would be that hard... Seems like everyone does rear sprockets...
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: filteredsoul on Dec 10, 2012, 13:59:25
Ok man...
Now I'm on a mission. Here's another place just in case:
Superior Sprockets. Located here in the USA (Oregon) 1-888-347-7267
http://www.superiorsprockets.com/
They will build you whatever you need... front/rear, whatever.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: filteredsoul on Dec 11, 2012, 13:52:15
Cool!
I'm glad they still had it!
I dig your project by the way... Your craftsmanship is exemplary. -don't know if I spelled that right...
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: skillz on Dec 11, 2012, 23:32:40
I know you will be using a mikuni carb, I was just curious if you ever looked into using the stock carb? I can't seem find much info on jetting the stock carb with pod filter. 
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: cierrecart on Dec 11, 2012, 23:39:57
I know you will be using a mikuni carb, I was just curious if you ever looked into using the stock carb? I can't seem find much info on jetting the stock carb with pod filter. 

I've exchanged a few emails with Jared at Holiday Customs who built the brat style Gn400  that was on Pipeburn.  He said the bike required no jetting with the pod filter on the stock Carb.  Says it runs great.  I'm hoping I'm as lucky.  :)
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: filteredsoul on Dec 12, 2012, 12:34:10
I've exchanged a few emails with Jared at Holiday Customs who built the brat style Gn400  that was on Pipeburn.  He said the bike required no jetting with the pod filter on the stock Carb.  Says it runs great.  I'm hoping I'm as lucky.  :)
You should be fine as long as you know what to do. I have a K&N pod on my bike (stock carb) and it ran good before I started this project bike. Folks will tell you that the GN will not run well with a pod filter, but it can. The main reason I wanted to go with a Mikuni VM is because it's a slide carb and not a CV. (plus it's more adjustable) The stock carb uses a vacuum activated rubber diaphragm to raise and lower the needle. If this rubber diaphragm gets old (as they all are...) it dries out, develops pin holes, becomes thin... etc. You lose vacuum pressure with these holes and your bike runs like crap. I could pretty much read a newspaper through my diaphragm so I "fixed" it by smearing a thin layer of "Hondabond" on both sides of the diaphragm. The Hondabond remains flexable and plugs all the tiny holes so the needle raises and lowers like it's supposed to. I'm sure I've added mass to the whole assembly by applying the Hondabond so my throttle response is probably not as crisp as a shiny new carb... but as far as the jetting goes, I went to my dealer and bought an assortment of main and pilot jets. I tried probably 3 of each. To me, (right off the Blue Ridge Parkway in the mountains of Asheville, NC... anywhere from 2000 to 5000 feet above sea level) the best combination with the pod filter was the stock size pilot, and 2 sizes up on the main. There is also an air screw that is "capped" at the factory. This screw (or cap) is visible from the top of the carb. It's the little silver aluminum cap in front of the big slide cap. Poke a hole in the cap with an awl, then pry it off. You'll see a little brass screw underneath. I had to play with this screw a little, but after the pod filter, the new main and a tweak of the air screw the bike runs at least as good as it did with all the stock airbox junk. Your results may vary, but in the end... it's just a simple engine with a simple carb. I'm sure there are many carbs that would work on our bikes. In fact, over in the UK Vic Camp was putting Amal's on his SP370 race bikes which would run at 120 mph!

Anyway, all that to say... it is possible to run this engine with a pod filter.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: cierrecart on Dec 12, 2012, 16:37:15
Lots of great info....thanks!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: skillz on Dec 14, 2012, 22:44:06
Guess ill start with the stock and see we're that takes me! Thanks for the info!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: cory.ahlersmeyer on Dec 17, 2012, 16:11:02
I'm getting a GN400 for freezies but I need a manual... do you happen to have one from your build?
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: peteGS on Dec 19, 2012, 08:05:45
Search eBay for the seller e-Classic Bike out of New Zealand.


He has a lot of factory reproduction manuals for very good prices. If he hasn't got one listed, he says to message him as he has access to more.


They come printed on decent quality paper and bound with a plastic cover.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: filteredsoul on Dec 19, 2012, 09:53:46
Go to this link:
http://autos.groups.yahoo.com/group/GN400/
It's a Yahoo group dedicated to the GN400. You'll have to "apply" to be in the group, but there is a ton of info there and everyone is very helpful. In the "Files" section there are a number of files that you can download for free that will result in a full manual. I've done this and combined all the files into 2 pdfs. misteroddjob is pretty much correct in that you'll need 2 manuals... the first one is for the Suzuki SP400 (not the 370) and there is a GN400 addendum to that. These 2 manuals will give you everything you need to be dangerous. I'd post them somewhere for download, but together they're over 150mb!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: StryfeS13 on Jan 09, 2013, 03:37:45
I remember reading a few pages back you mentioned that all of the early Suzuki GS (400, 425,450, 550, 750 & 1000) models have the same hub dimensions as the GN, so they're a bolt on swap. Does this mean that the spoke wheels from these bikes fit the GN too?

My GN came with gold mags and I hate it!

And what front disk are you using?
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: filteredsoul on Jan 10, 2013, 10:55:26
If you want a direct bolt-on swap, check ebay. Some models of the GN400 actually came with spoked wheels (instead of the gold cast alloy). There's always some on there.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: StryfeS13 on Jan 31, 2013, 23:05:00
Do you happen to know off the top of your head a capacitor that will work to replace the battery on the GN400? Mine is still 6v.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: Green199 on Mar 17, 2013, 15:36:01
Any progress on this monster?
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: lior_baruch on Mar 17, 2013, 16:52:01
Amazing project in SO MANY WAYS!

More updates... please... I'm begging...  8)
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: CafeRacer650 on Mar 18, 2013, 11:07:03
Hey Buddy!  Sorry I've been A-wall for the last few months.  I still would like to hit the mountains sometime.  Hope all is well. 
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: CafeRacer650 on May 01, 2013, 14:30:42
Any progress on your bike Jeff?
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: lior_baruch on May 04, 2013, 13:04:01
Nope, unfortunately I've had some family-related things that have taken up most of my time for the last month.

Take your time, your project worth the waiting ;)
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: CafeRacer650 on May 06, 2013, 10:52:06
Nope, unfortunately I've had some family-related things that have taken up most of my time for the last month.

Yes, do take your time.  It's been months since I've touched my bike due to other project issues.  No pressure.  Once there's some free time and a NON-rainy weekend, we need to hit the mountains!
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: stepside03 on Jun 13, 2013, 16:24:06
I have a used Clarke tank available in red. The pics below link to hi-res photos of it in my Flickr account. PM me if you're interested.
(http://farm8.staticflickr.com/7181/6923479292_e471b952a4.jpg) (http://www.flickr.com/photos/hallucid8/6923479292/)(http://farm6.staticflickr.com/5464/6923479504_63325df78b.jpg) (http://www.flickr.com/photos/hallucid8/6923479504/)
26442-45000
I'll be wrapping the bike up in the next month. I haven't had the time to work on it since Memorial Day. The seat will be custom made, so unfortunately you won't be able to just buy one.

you wouldn't happen to still have this would you? i know its from along time ago, and the tanks probably long gone. Also im loving this build its given me a lot of good ideas for my build. the form of your bike is great, the frame fenders tank alone sit so well. cant wait to see her finished.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: volthause on Jun 19, 2013, 14:37:44
I just went through this thread front to back. Really nice work. I admire your craftsmanship, and your patience to see this through without rushing it.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: SeekingZero on Jun 22, 2013, 03:01:47
Thanks for the kind words.
Things are looking good that my schedule will open up in about a month and I should be able to finish by the end of summer.

Looks like we both took a little longer than expected!  ::)

I would hope to have mine done by Vintage Days in July, but end of summer might be a better goal to shoot for.

Slow and steady my friend, slow and steady.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: ILoveThumpers on Jul 15, 2013, 12:58:45
Greetings! I've acquired a GN400 in practically perfect condition (sweet gold mags and all) but I'm very interested in converting to 12v and ditching the battery. I've been following this thread with interest ever since I ran across it looking for Cafe builds.(Nice work... you appear to be as anal retentive as I!  ;D)

Have you completed your 12v conversion yet? I've been looking at these Podtronics units (http://www.podtronics.net/) (specifically the 1P HP unit) but I'm curious about your results with the Sparx unit also. (Adding a capacitor to the Podtronix units should be easy enough, though)

Based on your description of the GN stator, it's a two-phase unit? So the pink wire (usually connected to an AC regulator) and the blue/white wire (usually connected to a DC rectifier) go to the two yellow wires on the new rectifier? That seems simple enough... thank goodness it's not a positive ground system!

Finally, could you post a link to the Sparx unit? I can't find much on eBay...

Thanks for such a detailed build thread! Looking forward to seeing it done (as I'm sure you are!)

-Deek
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: ILoveThumpers on Jul 16, 2013, 10:54:36
Gotcha. Thanks for the reply! (I didn't think to search completed listings)  ::) Duh.

-Deek
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: ILoveThumpers on Aug 07, 2013, 21:26:44
Wha? Where did all the posts go? There was a TON of great information here; now it's gone?

Did he move it to another thread or what?
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: jordanarmstrong on Nov 15, 2013, 23:06:53
Anyone know what happened to all of the posts on this thread? I'd really love to get some of this info. And to see the build of course.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: Big Rich on Nov 18, 2013, 00:17:01
Oddly enough, all the posts in this thread had been deleted (I would have to assume from the OP). No idea why, but it's a shame.

Mister Oddjob might have this build thread posted up on ADVRider? I'm not sure though.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: CafeRacer650 on Nov 21, 2013, 09:53:43
Jeff, misteroddjob, is on a hiatus right now.  Some of you might have met him at Barber this year, him and I rode there together.  His build is on hold for the moment.  Not sure if he'll be back. 
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: Big Rich on Nov 21, 2013, 11:09:52
Sounds pretty bad...... whatever the reasoning, I hope it all works out. Thank you for the update, sir.
Title: Re: Suzuki GN400 Scrambler/Cafe Hybrid
Post by: CafeRacer650 on Nov 22, 2013, 10:05:18
Nah, not bad.  I think he's just busy.