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GS400 restoration project

  • Thread starter Thread starter MarkoGS400
  • Start date Start date
M

MarkoGS400

Guest
Hi!

I am new user to this site and reason why I am here is that I bought a little project bike.
Suzuki GS400 year 1978!

Its totally detached in small parts in couple of boxes. Well, atleast it was cheap :-D


Here's a list of my questions:

Is there any good project stories about this bike?
What parts from other models are equal to this bike?

I'll add my questions here when I have time to start this project.

Here you can see couple of pictures from the day I bought this beauty :)
 
Last edited:
Welcome to the GS Resources, Marko... you've come to the right place!

Have you tried using the 'Search' feature to look for previous posts relating to GS400's? That would be a good way to start.

(BTW, I tried to follow your link to the pictures of your project, but simply got a 'page cannot be displayed' message.)

All the best,
Mike.
 
tfb said:
Welcome to the GS Resources, Marko... you've come to the right place!

Have you tried using the 'Search' feature to look for previous posts relating to GS400's? That would be a good way to start.

(BTW, I tried to follow your link to the pictures of your project, but simply got a 'page cannot be displayed' message.)

All the best,
Mike.
Click to expand...

Yeah I did try the search and I found many interresting topics that I'll will truly come back later on.
I'm preparing for forthcoming detaching and repairing and so now I'm going to do is try to find parts that I know that I'll need later.

So the important question is that: What parts from other models are equal to this bike?

I haven't seen so many GS400 parts and would be curious to try some GS425/450/500... parts but I it's hard to buy those without knowing if they will fit.
So my bike is made in 1978 so does the manufacturing year have any matter on fitting parts?

And that link. It works fine for me when I try to copy&paste the address but klicking is not working.

So try copy&pasting this to your browser:

www.tkk.fi/users/mrantone
 
Your best bet to find out if parts are interchangable is to use the Suzuki parts catalogue and look up the different part numbers and compare.

http://www.alpha-sports.com/suzuki_parts.htm

I can tell you that the 400 and 425 were very similar, the 450 is a little different and the 500 is a lot different. I'd be surprised if ANY parts interchange between your bike and a 500.

Good luck.
 
Just got back from checking out the photos Marko and I must say you have quite a big project on your hands. From the basic condition I'd say you better think long and hard about how deep you are willing to get into it. Those pistons have lots of blow-by so you are going to have to at least, re-ring it.

I say this from experience since I cleaned up a GS450 earlier in the year. Paid $200 for the bike and continued to spend $600 more on: tires, tubes, chain, sprockets, battery, gaskets, paint, manual, filters, oil, ect. At the end of the day, I had more into the bike than it was worth and mine was WAY less work than you have on your hands.

Good luck and keep us posted on your progress.
 
If you make a list of parts you need I will try and cross reference the parts at work as I work for a motorcycle parts and accessories company.
Good luck with the gs400,my gs425 is nearly finished and it is a great feeling to reserect a bike from the dead.
 
Yes, it looks like you have lots of work ahead of you there. And as Nessism points out, you will end up spending more than the bike is worth.

But hey, the reason I spend money on my old bikes isn't to make money! It's all part of the trade-off. I spend money, alright -- but I get lots of pleasure and satisfaction out of doing things right, and getting the machines running better and better.

And as the intro. to the GS Resources says, a GS will always turn heads. They are a classic machine, and in my opinion always worth rescuing from the scrap heap whenever possible.

So set about doing things methodically and properly, get yourself a manual, and you'll have a ball.
 
tfb said:
Yes, it looks like you have lots of work ahead of you there. And as Nessism points out, you will end up spending more than the bike is worth.
Click to expand...
I know that this will cost a lot but the idea isn't make money by selling this project later but the thing is to get my hands dirty and have fun making this bike running!

About those pistons. Those are maybe the reason why this bike is in small pieces. Luckily the former owner have repaired and redrilled cylinders.

There will be lot of work before this bike is running but hopefully we have at least mots of the parts. Starter and and some small parts are missing and some of the parts are just too rusty to repair.
The will also be a lot of paint work to do so this ain't a small project :)

Thanks for that parts link!
I already have parts catalogue for GS400C and I have to get that manual. I think this works fine?
 
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Check ebay for a factory service manual. They usually sell for less than that Clymer and are far superior.

You mention "redrilled cylinders", do you mean they have been bored oversize? Is so, you are going to need oversize pistons and rings as well.

You might want to check out this thread on a guy that is restoring an old GS. He is doing the job the right way: sandblasting the frame and such.
http://www.thegsresources.com/_forum/showthread.php?t=89601

Good luck!
 
MarkoGS400 said:
I know that this will cost a lot but the idea isn't make money by selling this project later but the thing is to get my hands dirty and have fun making this bike running!
Click to expand...


That's the spirit that started my obsession with motorcycles! Take my advice, though: Remember that idea when you're sitting there saying "Where the @#$# does this go?" Trust me, it'll all be worth it when you finally do get it on the road. Knowing you're riding a bike that YOU put together, YOU rescued from the grave and YOU know front to back is one of the best feelings in the world.
 
Nessism said:
Check ebay for a factory service manual. They usually sell for less than that Clymer and are far superior.

You mention "redrilled cylinders", do you mean they have been bored oversize?
Click to expand...

Yeah, by redrilled I meant that the cylinders are bored oversize and because of that it certain that I need correct size pistons. Of course.

txironhead: Sounds great and that gives me spirit to continue this project!

I ordered that Clymer manual and I hope it will help me forward.
I'll keep you posted when this project continues! :)
 
ive got a gs400 too

ive got a gs400 too

ive got a gs400 im gonna facelift and tidy up,,how you getting on with yours ,perhaps we could share tips and advice
 
They are great bikes, and fairly simple to work on.

As far as parts availability, it can be a little rough, since there aren't too many of them out there. The engine is essentially the middle of a GS750 of that era, so the pistons/rings are interchangable, and the front brake caliper/rotor was used on some other models, so you can get rebuild kits.

The '77 and '78 are virtually identicle except for some minor jetting; the crossover on the exhaust, and a few other things. I detailed most of that in another thread you should be able to find with a search.

The manual will work fine, but you should look for a factory manual as well. Here's one on eBay that should cover your year - reasonable price as well. http://cgi.ebay.com/ebaymotors/SUZU...018QQitemZ280030733263QQrdZ1QQsspagenameZWD1V
Here's another slightly more expensive... http://cgi.ebay.com/ebaymotors/1976...014QQitemZ330008626830QQrdZ1QQsspagenameZWD1V

I think they should cover the '77 and '78, but you might ask. There are also several owners manuals on eBay that might be usefull.

I have part number cross reference software, so if you have specific parts you want to know about interchangability on just post the question and I'll probably see it adn let you know.

Good luck and have fun...
 
Also, let me know if you need info about how things go together, wire and cable routing, etc. I can send pics.

Here's my '77 GS400 for inspiration. Bought it new in spring of 1977:
bom-650.jpg


and links to a few more pics:

http://home.sprintmail.com/~pmusser/sitebuildercontent/sitebuilderpictures/400sm.jpg
http://home.sprintmail.com/~pmusser/sitebuildercontent/sitebuilderpictures/400engsm.jpg
 
ptm said:
Also, let me know if you need info about how things go together, wire and cable routing, etc. I can send pics.

Here's my '77 GS400 for inspiration. Bought it new in spring of 1977:
bom-650.jpg


and links to a few more pics:

http://home.sprintmail.com/~pmusser/sitebuildercontent/sitebuilderpictures/400sm.jpg
http://home.sprintmail.com/~pmusser/sitebuildercontent/sitebuilderpictures/400engsm.jpg
Click to expand...

Hi, that GS truly looks sweet! =D>

I have been able to work with my bike for only one weekend for this autumn/winter and disassembled the whole body and I'm going to sand blast the body and tank and later I'll take it to painter. Any advises for that procedure?

I assume that your bike is made for US markets and there are several other versions in european market? Since my GS400 is produced for Finnish/Scandinavia markets I think that there are some differenced with your bike. Is there any list where I can see all the differences with US-German-Finnish models?

Right now I'm missing starter and some parts from starter clutch set and contact breaker. Also some smaller parts aremissing but I can buy those when I'm assembling this bike.

I also noticed that my bike have had these small decals on the tank sides http://www.suzukicycles.org/photos/suzuki-history/1978/1978_GS400_450.jpg. I can see that your tank is only painted. Any idea where I can find these decals?

I also have a little problem finding out if my front fender should originally be chrome or painted red. I found lots of pictures (from Finnish GS400) where there is red fender but there is also lots of pictures with chrome fender!

Next thing I'm going to do is break that motor apart and see whats going on in there. So I would need to find all gaskets, oilseals and bearings. Can't find those anywhere! Full gasket-set would cost well over 100?=$125 at my local parts dealer! Any idea where I could order those for cheaper?

I'm sorry about my bad English and these terms :oops:
 
In addition to suzukicycles.org, another site that is useful is Alpha Sports http://www.alpha-sports.com/suzuki_parts.htm It uses actual Suzuki part numbers which is helpful. It also shows another part that fits when the original is no longer available.

I don't know any where to find differences between the models sold in different countries. Search the Web - you might find something.

Complete gasket sets are available on eBay. here are a few I found with a quick search. They're not cheap, but better than buying them individually.
http://cgi.ebay.com/ebaymotors/Suzu...ryZ34284QQrdZ1QQssPageNameZWD1VQQcmdZViewItem
http://cgi.ebay.com/ebaymotors/Suzu...ryZ35595QQrdZ1QQssPageNameZWD1VQQcmdZViewItem
http://cgi.ebay.com/ebaymotors/COMP...ryZ35595QQrdZ1QQssPageNameZWD1VQQcmdZViewItem

You can find a lot of good used parts on eBay - just look carefully at the seller's feedback.

The link to your decal picture didn't work, but I had none on my tank. There were decals (GS400) on the black side panels that I removed (when I was young and foolish). I found a company that made reproduction decals that were very similar, but I can't find their link right now. I'll look more later.

All the 400s I've seen have chrome front fenders, but there may be some that don't, or someone may have painted over the chrome.

No need to apologize for your English - it's very good.

Have fun.
 
Here is a link to a bike that have decals on tank. I can see that my bike have got decals in tank but some one have taken them of.
Here is a link to a bike that have red painted front fender. I dont know if that is original fender but my fender is also painted red. I'm not sure if I have to buy a new one because thats not in so good shape. By the way this bike doesn't have decals on tank but it's not so original looking anyway.

I've been looking part numbers from that Alpha Sports site and it's been very helpful.
Thanks for those ebay links. I might consider ordering some of those and hopefully the postage fees and taxes aren't so big.
Thanks Gerkin for that German site! Learnt something new :)
 
just as lost

just as lost

Hey Mark

I just bought what is supposed to be an 81 GS400, and I'm also struggling with finding parts.

Most of my problems are front-end related, and some parts of the bike are held together with rubber bands and twist ties. I'm having trouble with my front forks and front brake.

I have some metal/body work experiance. It may be possible to salvage the old front fender, assuming it is still mostly metal and not rust.

If you can post more pictures of the front fender I can have a look and see if I can tell you anything useful.

BentRod
 
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