Suzuki GSX400 brat\cafe build- It's back on the road!

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eran_k

Been Around the Block

• Feb 5, 2013

• #1

*** see update on last post ***
Hi There,
This is my first project on the site and my first cafe build.
I bought a 1984 Suzuki GSX400 with title and it came with another 1987 bike with no title as parts doner.
both bikes are complete...more or less but, the titled bike is starting and keeps idle, all the rest needs TLC. i dont know what's the 1987 engine condition.

The plan is to tear down the "good" bike, modify the frame and putting it back together while utilizing the best parts from both bikes, off course i'll fix\rebuild\replace as needed.

I only have the weekends to work on the bike so the progress will be slow :-\

I'll start with the pictures

Bikes the day i got them - the red is the titled one

Started to take it apart

Parts are piling

Exhaust gave me hard time to pull aprt the connection, eventually i had to cut it with the grinder

Motor is out

And we have a rolling frame

 

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eran_k

Been Around the Block

• Feb 5, 2013

• #2

Re: Suzuki GSX400 Project Cafe (Maybe?)

Next weekend, moving on with the tear down

Down to bare frame

Started to De tab

Next task is to decide about a gas tank, the original tank is 80's style and has a side cover mounting that's ugly. if i wont find another more "classic" tank i'll have to fill in that section and use this tank.
Iv'e tried couple of other tanks but somehow they'r all to narrow in the middle.

 

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eran_k

Been Around the Block

• Feb 5, 2013

• #3

Re: Suzuki GSX400 Project Cafe (Maybe?)

I did a little "mock up" with my tank and a cafe seat borrowed from a friend (it's to narrow for my frame).
IS the tank ok? Caf'eish enough?

If i'll stay with this tank, i'll cover those mounts at the side with metal or fiberglass.

 

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eran_k

Been Around the Block

• Feb 6, 2013

• #4

Re: Suzuki GSX400 Project Cafe (Maybe?)

Do you know if a GS 450 Tank will fit? i know i will need to modify the rear mount, but will it fit over the frame?

 

Big R

Heaven is so far away.

• Feb 6, 2013

• #5

Re: Suzuki GSX400 Project Cafe (Maybe?)

I would imagine it could.....give me a couple days and I could possible measure my 450 frame / tank if you'd like.

 

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eran_k

Been Around the Block

• Feb 6, 2013

• #6

Re: Suzuki GSX400 Project Cafe (Maybe?)

Big Rich said:

I would imagine it could.....give me a couple days and I could possible measure my 450 frame / tank if you'd like.

Click to expand...

That would be most kind, Thanks

 

gk45011

Coast to Coast

• Feb 6, 2013

• #7

Re: Suzuki GSX400 Project Cafe (Maybe?)

Eran,
I am using the same tank from GSX450 on my cafe build. I would eventually like to re-do my seat pad to wrap and cover the area you are talking about. If you want an idea of what it looks like on the bike you can check out my build thread.

I'm jealous of the two bikes. Sounds like you got a great deal. Pleanty of Suzukis popping up on here lately. If your not a member get on the GS Resources as well. They are great with the technical/mechanical end over there. Rich,Pete,Alpha and a few on this site are resident GS experts as well and have some great knowledge to impart.

I'm on board with your build,

Gary

 

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eran_k

Been Around the Block

• Feb 7, 2013

• #8

Re: Suzuki GSX400 Project Cafe (Maybe?)

Hi Gary,
I'm following you'r thread, and because of it I'm thinking about using this tank after all instead of going thru all the trouble of first finding and then fitting another tank. already tried that with 2 other non Suzuki tanks and the tunnel is just too narrow (even with the coil mount removed)
I'm a member in GS Resources, and have a paralel build thread over there.

I think I'll try to cover those mounts on the tank either with sheet metal and bondo or fibreglass.

 

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eran_k

Been Around the Block

• Mar 3, 2013

• #9

Re: Suzuki GSX400 Project Cafe (Maybe?)

Not much to update, I'm waiting for a new tank i got on ebay to arrive, until i fit it i can't do too much in terms of welding and painting the frame.
In the meanwhile i'm cleaning and fixing components like the calliper, MC and so.
Also built a little engine stand so i can work on the engine, i emptied the oil and took off the side covers, where a nasty surprise waited under the generator cover. two of the magnets are shattered and the whole place is filled with oily magnetic debris, the coils don't look to good either. it's a good thing i got a second bike for parts i just hope they will be decent.
I need to figure out how to take the rotor out without an impact wrench.
and now some pics to follow all the long and boring story

 

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Pod70

Active Member

• Mar 3, 2013

• #10

Re: Suzuki GSX400 Project Cafe (Maybe?)

The rotor is fairly easy to remove.
Undo the centre bolt, Cut a short length of stud, I think 8mm will fit and place where the centre bolt was. I can't remember the length but look in the rotor and you will see a large thread (not the thread in the crank). The stud needs to be below this. Take the rear spindle and thread it into the rotor, the thread is the same. Gently tighten the spindle and the rotor will pop off the taper (possibly with a bit of a bang). If you need to lock the engine, stuff some rag between the clutch and crank gears. When you turn the engine, the rag will jam.

 

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eran_k

Been Around the Block

• Mar 3, 2013

• #11

Re: Suzuki GSX400 Project Cafe (Maybe?)

Pod70 said:

The rotor is fairly easy to remove.
Undo the centre bolt, Cut a short length of stud, I think 8mm will fit. Take the rear spindle and thread it into the rotor, the thread is the same. Gently tighten the spindle and the rotor will pop off the taper (possibly with a bit of a bang).

Click to expand...

So far i did not succeed in opening the bolt, i need to find a way to keep the motor from turning.

 

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Pod70

Active Member

• Mar 3, 2013

• #12

Re: Suzuki GSX400 Project Cafe (Maybe?)

Just added to my post, hope that will explain

 

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eran_k

Been Around the Block

• Mar 4, 2013

• #13

Re: Suzuki GSX400 Project Cafe (Maybe?)

Today i got a GS450 Tank, now i can move forward with the build.

I was hoping it will fit without any modifications but it will need some work, the front mounts are too long and for the rear i need to fabricate a new mount (this tank uses a single bolt at the back)

 

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eran_k

Been Around the Block

• Mar 11, 2013

• #14

Re: Suzuki GSX400 Project Cafe (Maybe?)

well since i only get few hours a week to work on the bike, my progress is slow.

I bought a very useful tool today

Got the rotor off after lot of effort, i think i jammed a piece of metal in the crank shaft and will need to extract it

Also took the clutch basket out in order to change the shift shaft
i will replace the springs, do i need to replace the friction plates?

The paint on the covers was a nightmare to chemically strip, it's the factory PC i guess. so i ended wire brushing it off. i will either polish or repaint the covers, haven't decided yet.

 

Lid

New Member

• Apr 16, 2013

• #15

Re: Suzuki GSX400 Project Cafe (Maybe?)

Great fun to read a thread about another Sukkisukki-400 café. Im building myself one too.

I use a tank from a GS550 on my gsx400e. I sounds like you got the same issue with the front mounts.
I removed the stock rods and drilled a 10mm hole about 7mm on top of where the old rods were, for clearence and just took a 66mm M10 threaded rod, with two nuts and M10 washer on the rubber side.

Hope you update the progress soon. Ive bookmarked this thread
Jesper from Sweden

 

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eran_k

Been Around the Block

• Apr 18, 2013

• #16

Re: Suzuki GSX400 Project Cafe (Maybe?)

Finally i was able to get things going again, got the frame to the welder and we started to work.

First, we made front and rear mounts for the gas tank

then, we shortened the tail and welded the hoop

next would be fabricating a seat pan and under seat tray for mounting all the electrical stuff.

Eran

 

Big R

Heaven is so far away.

• Apr 18, 2013

• #17

Re: Suzuki GSX400 Project Cafe (Maybe?)

Coming along nicely Eran!

Is there more support for the rear tank mount? I'm just concerned about how well those 2 little welds will hold.

 

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eran_k

Been Around the Block

• Apr 19, 2013

• #18

Re: Suzuki GSX400 Project Cafe (Maybe?)

Big Rich said:

Coming along nicely Eran!

Is there more support for the rear tank mount? I'm just concerned about how well those 2 little welds will hold.

Click to expand...

This is actually a thick piece of angle iron /\ and it's welded from behind as well, very sturdy
Thanks for your concern

 

Big R

Heaven is so far away.

• Apr 19, 2013

• #19

Re: Suzuki GSX400 Project Cafe (Maybe?)

Ah, ok. I figured there was more than what the pics showed. Just checking!

 

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eran_k

Been Around the Block

• Apr 24, 2013

• #20

Re: Suzuki GSX400 Project Cafe (Maybe?)

Had few hours so went to my welder guy, today's labor was the seat pan and it's brackets