Restoremod Suzuki GS400 E

[HAMMERHT]

Hello, I am finally going to do what I?ve always wanted to do. I own an 86? GS400 E.
I have questions on how I should proceed with this rebuild.
I have a spare engine for the bike which I plan to rebuild.
I also want to update the suspension system, replace the rear shocks.
The wiring harness is a mess, one because it?s 30+ years and it?s been fiddled with by previous owners. I am aware that rewiring can be complicated so I may outsource that job.

I have an LED bulb for the headlight, the front rotor has been replaced with an EBC one with new pads and I repainted the bike purple.

For the engine rebuild, I have found the service manual from BikeCiff?s wonderful resources.
I have many tools but I know I need some speciality tools specifically for the engine rebuild.
What tools do you guys use for your rebuilds?
Tips and pointers are appreciated.

[Guest]

Do you want your restoration to be mild or wild? Return it to stock performance or try to push the envelope?

[HAMMERHT]

For the engine, I will not be putting on any parts to increase the hp. I figure since the engine has over 90K that some ponies have been lost and a rebuild with OEM parts should be fine.
Suspension: I want to replace the rear shocks, I don't plan to take it racing but I would like to find a set of aftermarket shocks that perform well on the highway traveling with luggage and on windy roads. The front I wont be doing much except putting in a "stiffer" fluid.
Brakes have been upgraded already with HEL braided lines and EBC rotor and pads.
I am leaving the air box in since I don't want to deal with the issues pods can bring.
Maybe have an exhaust system made for me since there is very little aftermarket parts for this model of GS.

[eil]

and I repainted the bike purple.

Now wait just a minute, you can't make that kind of assertion without photographic evidence.

[eil]

I have many tools but I know I need some speciality tools specifically for the engine rebuild

Probably not as many as you think. Off-hand, the main "specialty" items that I can think of are the tools for measuring the bores, pistons, cams, etc. A cylinder hone. Torque wrench, of course. There are a few "special" Suzuki tools that the factory service manual call for but in most cases they aren't strictly necessary and the job can be done with regular tools and an alternate approach.

[HAMMERHT]

@eil

Here's your photographic evidence.
https://www.instagram.com/p/B1m8kH2gbek/?utm_source=ig_web_copy_link

[Guest]

@eil

Here's your photographic evidence.
https://www.instagram.com/p/B1m8kH2gbek/?utm_source=ig_web_copy_link

Nice! I would add that while not strictly necesssary, a motorcycle specific engine stand will make your life a whole lot easier - allows you to rotate the motor 360 degrees to work on it.

I loved my K&L stand when I was building my GSXR 750 motor:

[HAMMERHT]

That's a good tip!
They look pricey though so I might find some specs and build mine.

[Rob S.]

@eil

Here's your photographic evidence.
https://www.instagram.com/p/B1m8kH2gbek/?utm_source=ig_web_copy_link

Am I the only one who can't see any "photographic evidence"?

[HAMMERHT]

LOL.

https://www.instagram.com/p/B1m8kH2gbek/?utm_source=ig_web_copy_link

I think this should work.

[Guest]

That's Plum Crazy....

Parts are getting a bit thin for the 4 valve 400s now. In theory, the later motors had less tendency to crack at the plug holes, which can be rather disheartening to find. I'd shine a light down the plugholes to see if they're cracking upwards from the bottom. Gaskets are still around somewhere - check cmsnl.com - and as I recall, rings can be substituted with Yamaha 225 rings [maybe, perhaps] but I would hesitate to tear the thing apart unless you have low compression or oil consumption woes, and I'd fully suss out the parts supply, especially gaskets, before tearing it down.

As a last resort, you could swap a 450 top end on your block, but you have to replace everything. I've done it twice and it's no big deal, but it's a long shopping list of parts to find.

[HAMMERHT]

Thanks for the heads up.
I am aware that spare parts are hard to come by with this type of engine, which is a shame.
I originally wanted to get this started by start of 2020 but business for me has slowed down and I may need to move soon.

I know there is a Suzuki specialist shop in Vancouver with a large inventory of classic Suzuki parts. And my local Suzuki dealer has been pretty good in finding parts.
I understand what a lot of you think, why rebuild an engine if it doesn?t show any issue. The engine just past 90,000 km. I don?t know when the last time the engine was rebuilt, if ever. I?m up for the challenge, plus I have a spare engine that I am also going to disassemble and use it for a parts engine. It also has 90,000+ km on it.

[steve murdoch]

Thanks for putting up the photos of the bike/car show.
Looks like a nice event with a huge variety of vehicles.

[Guest]

I see that cmsnl.com has standard rings and also the head gasket, which is a new and improved type with sealing rings at the oil feed studs. Although I've never seen much problem with leakage, I'd opt for this version over the original. It's Suzuki part # 1114144110H17. 72 euros.

The only oversize piston/rings is a .5mm over at $82.50 plus rings @ 38 euros. The do have intake boots for 53 E a pair.

Cams and cam followers can be problematic if the valves haven't been kept adjusted; easy to check. Usually the follower gets a trench in it and then beats up on the cam for revenge.

But it's good news on the parts front compared to the drought of a few years ago. That said, this company buys up old dealer stock and the quantities can be minimal so I'd get into the top ends of these motors [order the gaskets first] sooner rather than assuming what you can get today will still be there in future.

[Rob S.]

I understand what a lot of you think...

I was thinking that a restomod on such a small bike was unusual.

Restorations we see on all sizes of bikes. But restomods seem to be on liter or bigger, rarely smaller than 750.

But whatever floats your boat. I'm guessing the 400E was part of your youth.