81' GN400 Build Cafe/Brat

Re: GN400 Build Cafe/Brat

skillz said:
Is that a pic before or after you took 2 inches out of the springs? .. Noticed the top of the forks still pop up out of the trees. Is 2 inches the most you can chop out of the springs or can you cut as much as you want? Nice lookin build so far !

In that picture the forks are lowered 2" internally. The reason they are still lowered in the triple trees is so I can fit my clip ons. You can lower them more then 2" internally if you want but I didn't want to.

The forks on the GN are outrageously long though. Even lowered 2" they are still taller than my friends stock GS550 forks.
 
Re: GN400 Build Cafe/Brat

Got some progress done today with the GN!

My clip-ons arrived, and so did my black o-ring chain. The clip-ons are a little long but they are adjustable so that can be fixed of course!

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Then I started making a template for my seat pan...ghetto but it works!

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I went to work for a little bit and glassbeaded my gas tank...I will be painting it black I think. The bare metal look is a little played out.

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I cut out and started shaping the rear half of the seat pan

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Now I just need to weld the pan together and get it upholstered.

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I tossed the motor in to see what it looks like. The tank will not be that bare metal look when finished.

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After I get the wiring and all misc brackets/odds and ends done I have to strip it back down to the frame because I've decided to re-paint it. The current paint won't fully cure. So I might powder coat it...Idk yet though.
 
Got some more work done to the seat pan.

Welded the two halves together and ground it down..

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Shaped it a little better..

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And then I mounted/welded studs for it to mount to the frame

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Can anyone help me out? I'm trying to delete the battery from my GN400 and replace it with a capacitor. Does anyone know what capacitor size I'd need to use? I'm not really familiar with this.
 
This guy is building a gn400 as well, and really knows his shit. Scroll to the bottom of the page to the link below.

http://www.dotheton.com/forum/index.php?topic=35688.30
 
Got some shocks to test fit from work today, some Red Kote, and a battery. It's a little big but it'll work.

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Got the frame all re-painted with some PJ1 and it's holding up a lot better than the rustoleum I used before. Started putting it all back together...I put the new shocks on it but I think they are too long..? Opinions? Keep in mind the bike is leaned on the side sand so it may appear higher. The new shocks are 13.5" eye to eye. I dont know if I like them...I mean it evened out the front and rear but I swear they look too tall.

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Also I coated the inside of my tank. This stuff is pretty cool

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Painting motor mounts before I re-install the engine..

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Well the bike is all back together for good this time...And it runs with the VM36 on it

A familiar sight of everything tossed around the garage lol

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All cables and everything back on. Carburetor, brakes, etc.

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Did some work on the tank and primered it. I think I might keep it this color! Looks pretty cool.

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Speedometer, clip ons, etc.

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And I also adjusted my valves. Manual says to tighten them all the way and back out 1/8 (45 degrees) of a turn. Was pretty easy.

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Now what's got me hung up is the wiring on this bike. Here's some pictures maybe someone can help me out?

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check this diagram... should be helpful... if you searched a little harder you might find a color one...
http://www.wiringdiagrams21.com/wp-content/uploads/2008/06/suzuki_gn400_wiring_diagram.gif
 
wership said:
check this diagram... should be helpful... if you searched a little harder you might find a color one...
http://www.wiringdiagrams21.com/wp-content/uploads/2008/06/suzuki_gn400_wiring_diagram.gif

Well, I'm not the best with wiring diagrams but if I'm following it correctly, the the "pink" (red) wire coming from my magneto goes to my lighting switch, which is odd, because there is no connector to go to it.

And the white/blue and red wires are supposedly my rectifier which is impossible because as you can see the rectifier is gray and ground.

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can't seem to find the random red wire that i think is the + cable, or that black box thing.
 
your "red" wire from magneto should be R/G or red/green, which is not in the key, but it goes straight to the CDI unit...
if it is the "pink" then it looks like it becomes yellow/red after the connector...

i really like where your bike is going, but i dont have the same bike so thats about as much help as i can give... check with some other owners and see if they can guide you...
 
Well I rode it for the first time! I'm using a TM36 Mikuni carburetor though and it's having a rich running issue. It'll bog down badly at WOT. But it was still a blast to ride!
 
Maybe someone can help me?

This is my issue with the stock carburetor...

http://www.youtube.com/watch?v=dADsmKg0LlI
 
Well I just bought a 17" Emgo Reverse Cone muffler and a Sigma 6 jet kit, as well as a parts carburetor from cierrecart that has a good diaphragm in it. Maybe I can get this thing running better.
 
I fixed it! Always something so simple lol.

This whole entire time I have been scratching my head, thinking, "WHY is it running rich when it has a pod filter and open exhaust!?" and I was sitting there today and I was like, oh...because it's only running with the choke on, making the plug black. So like I've been thinking the whole time, it's running lean of course. I taped up the air filter and poked 3 little holes in the tape and it runs PERFECT. So I just need to jet it way up.

:)
 
Looking good! Just started my own GN400 project a couple of weeks ago. I just came across your build and I can't wait to see how it all turns out. I've been trying to decide whether or not to replace the carb with the Mikuni VM carbs. Just wondering why you decided it was best to replace yours. It might be too late, but I have the schematics for the bike in microfiche. Let me know if you need any of them. I need to make another trip to the library to put them all on a USB, but I'd be more than happy to share when I've got them.
 
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