Something a little different...Suzuki GN400

[StryfeS13]

I'm not sure how many of you will appreciate this, since most of us Zilvians are stubborn assholes. But I wanted to share this with you guys. This is a bike I just recently built and sold for $1500. I'm kind of regretting it, I thought it was really unique and cool.

I work (used to) at a motorcycle salvage yard in Fresno, CA and I stumbled across this GN400 in the lot one day. The reason it struck me was simply because of the big single and kick start, I had to have it!

So I brought the bike home from work and started tearing it down and turning it into what I want it to be, and this will be my build thread. My build is much inspired by the Holiday Customs GN400..

So this was the first day that I had the bike..it was pretty ugly haha!

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/CAM00907.jpg

First thing I did when I got it home was check for spark and clean the carburetor. I'm no longer using this carburetor though because I picked up a VM36 at work..

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0207.jpg
http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0208.jpg
http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0217.jpg

The gas tank was very rusty inside and still is...I need to clean it out still

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0230.jpg

And here's how it looked after I took everything I didn't like off.

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0237.jpg

[StryfeS13]

I decided that I didn't really these huge brackets so I removed them..

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0238.jpg

I bought some drag bars but I'm seriously considering going with clip ons instead..

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0240.jpg

Painted my stock mags black..I don't know if I'll like how these look or not. If I don't like them I'll get spoke wheels.

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0328.jpg
http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0329.jpg

I pulled the motor out to freshen it up, clean it, paint it, etc.

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0383.jpg
http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0384.jpg
http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0385.jpg
http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0386.jpg
http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0388.jpg

Also, I removed the "D" in the intake port (not cleaned up yet)

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0352.jpg
http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0353.jpg

[StryfeS13]

I bought some stuff from DCC and it arrived! Rear hoop, speedometer, frame slugs, headlight brackets

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0390.jpg

De-tabbed my frame..

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0403.jpg
http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0404.jpg

Rear hoop ready to be modified and welded on...frame slugs needed to be ground down too. I used a drill and grinder

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0405.jpg
http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0409.jpg
http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0412.jpg

Frame slug ground down (left) frame slug from DCC untouched (right)

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0413.jpg

Then I decided I wanted to cut the frame shorter so I marked it and cut...

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0416.jpg

Cut the rear hoop to the length I wanted it. It was too long.

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0418.jpg

Fit the slugs into the frame, welded rear hoop on!

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0422.jpg

And done!

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0423.jpg

[StryfeS13]

Been pretty busy but got some progress done. Installed swingarm and rear shocks...started electrolysis on my tank - trying to get the rust outta there

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0425.jpg

I work on and have 240SX's so I used one of my old Tomei stickers on the swingarm and it looks pretty cool haha..

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0426.jpg

My rust removal contraption lol

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0427.jpg

Painted the triple tree with some rustoleum "appliance" epoxy. Heard good things about it

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0438-1.jpg
http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0432.jpg

[StryfeS13]

For some reason the only fork seals that would fit my forks were ones from a TZ250..so I used those. The GN400 fork seals I ordered were 35x48x11 which were too tall for my forks, I needed an 8/9.5 (tz250, xj550, etc)

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/CAM00970.jpg

I also did some more electrolysis in my tank..gross!

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/CAM00967.jpg

I'll be lowering my forks 2" internally. Here are my forks all torn apart..

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/CAM00956.jpg

So I finished lowering my forks and also used some aircraft stripper to remove the yellowing clear coat that was on the lower tubes. I wanted to polish my lowers instead of painting them since there is already a lot of black on the bike.

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0446.jpg

I also got the bike rolling again! It will have to come back apart though, I have to re-paint the front wheel and maybe the frame...the frame paint I used seems to just chip off with my fingernail. Anyone got some suggestions for good frame paint?

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0448.jpg
http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0447.jpg

[StryfeS13]

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!

http://i1177.photobucket.com/albums/x343/Sickfire/IMG_0450.jpg

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

http://i1177.photobucket.com/albums/x343/Sickfire/IMG_0453.jpg
http://i1177.photobucket.com/albums/x343/Sickfire/IMG_0452.jpg

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.

http://i1177.photobucket.com/albums/x343/Sickfire/IMG_0464.jpg

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

http://i1177.photobucket.com/albums/x343/Sickfire/IMG_0466.jpg
http://i1177.photobucket.com/albums/x343/Sickfire/video4.jpg
http://i1177.photobucket.com/albums/x343/Sickfire/video3.jpg

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

http://i1177.photobucket.com/albums/x343/Sickfire/IMG_0474.jpg

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

http://i1177.photobucket.com/albums/x343/Sickfire/video2.jpg
http://i1177.photobucket.com/albums/x343/Sickfire/IMG_0475.jpg

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.

[StryfeS13]

Got some more work done to the seat pan.

Welded the two halves together and ground it down..

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0485.jpg
http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0486.jpg

Shaped it a little better..

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0487.jpg
http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0488.jpg

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

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0489.jpg
http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0490.jpg

Got some shocks to test fit from work today, some Red Kote, and a battery. It's a little big but it'll work.

http://i1177.photobucket.com/albums/x343/Sickfire/IMG_0491_zpsec2f23fe.jpg

Made a battery box that mounts under the seat pan.

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0493_zpsd321af60.jpg
http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0494_zps257f1a62.jpg
http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0496_zps66c7159f.jpg

[StryfeS13]

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.

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0500_zpsf210cefc.jpg
http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0499_zpsdf33a6d0.jpg

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

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0498_zps46f9b0df.jpg

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

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0497_zpsaa39cc2a.jpg

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

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0507_zps577a4949.jpg

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

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0508_zps9d54fc3a.jpg

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

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0515_zps937543c5.jpg

Speedometer, clip ons, etc.

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0516_zpsb73fc093.jpg

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.

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/IMG_0517_zps30f33b29.jpg

[StryfeS13]

Here's the seat after I upholstered it...

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/CAM01009_zps6671d49c.jpg (http://s1177.photobucket.com/user/Sickfire/media/GN400%20Cafe/CAM01009_zps6671d49c.jpg.html)

And this is how it looked around the time when I sold it. I don't know why I do this, but whenever I finish a project, I sell it...Anyway, that's the build thread - hope you guys enjoyed this short little project.

http://i1177.photobucket.com/albums/x343/Sickfire/GN400%20Cafe/CAM01076_zps4cc464ef.jpg (http://s1177.photobucket.com/user/Sickfire/media/GN400%20Cafe/CAM01076_zps4cc464ef.jpg.html)
http://i50.tinypic.com/11tu8nk.jpg

[HiddenCharacter]

Nice, ended up looking way better than when you first got it.

[TheRealSy90]

Man that thing was cool. I can't wait to build my first bike.

[Agamemnon]

The bike looked like it was fun to ride.

You should do a Japanese bobber now.

[StryfeS13]

Nice, ended up looking way better than when you first got it.

Thanks man!

Man that thing was cool. I can't wait to build my first bike.

Yeah it was. I've built a lot of bikes since I used to be a motorcycle mechanic. I sold this thing for only $1300.

The bike looked like it was fun to ride.

You should do a Japanese bobber now.

Super fun to ride! Weighed in at less than 280 lbs.

My friend and I actually just built a GS550 monoshock bobber. Here's a picture of it when it was about 1/2 way finished. I'll see if I can get some updated pics.

http://i199.photobucket.com/albums/aa174/chrisxxx07/65555_592088220820249_1898084206_n_zps658ff137.jpg

[StryfeS13]

Okay...?
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