1984 Suzuki GSX 400T

GSX400T Engine

The engine of our 1984 Suzuki GSX400T has been with Mauro in the Bridge Classic Cars paintshop. After prepping the engine, it was then painted

Read More »

More Progress

More progress has been made on the restoration of our 1984 Suzuki GSX 400T. The switch has just arrived and is very flat across the

Read More »

Almost There

Our 1984 Suzuki GSX 400T is almost at the end of its restoration journey. Although there is still some work to be done, as you

Read More »

Almost Up And Running

Our 1984 Suzuki GSX 400T has continued its restoration progress. The headlamp bracket and the rear lights still need to be sorted and all of

Read More »

GSX 400T Progress

We have recently received an update on the progress of our 1984 Suzuki GSX 400T. The frame and smaller parts of the bike are being

Read More »

Getting Some Sun

Our 1984 Suzuki GSX 400T was able to enjoy some time in the sun recently. After being in the workshop of JAL Restorations for a

Read More »

Progress Images

After the recent progress update that we received from JAL Restorations about our 1984 Suzuki GSX400, we have now received some images of the bike

Read More »

GSX400 Progress

Our 1984 Suzuki GSX400 has been with JAL Restorations for a little while now as they work on bringing this classic bike back to life.

Read More »

Custom Made Battery Box

Our friend Clinton from Holdsworth Artisan Metalwork has made this custom battery box for Craig’s 1984 Suzuki GSX 400T cafe racer motorbike. Clinton has carefully

Read More »

Welcome Back Home

Craig’s Suzuki GSX400 Custom has come back from Demand Engineering where the exhaust was being fitted. It was a tough decision between a short or

Read More »

Dan’s In Demand!

Our Director Craig has had a bespoke exhaust made for his 1984 Suzuki GSX 400T. The custom-built exhaust is the handy work of the genius

Read More »

GSX400T Engine

The engine of our 1984 Suzuki GSX400T has been with Mauro in the Bridge Classic Cars paintshop.

After prepping the engine, it was then painted in satin dtm.

Complete And Returned Home

It’s always exciting to see a project come to a conclusion. Recently, we were extra excited to see one of our own vehicles finish its restoration journey and return home to its owner – Bridge Classic Cars Managing Director, Craig’s motorbike.

Our 1984 Suzuki GSX 400T is complete and, as you can see from the photos below, it’s looking incredible.

There’s no doubt that Craig will enjoy his bike and we look forward to seeing it out and about.

More Progress

More progress has been made on the restoration of our 1984 Suzuki GSX 400T. The switch has just arrived and is very flat across the top. The speedo pops up 20mm and has a convex glass so you don’t have to be over it to read it with a fully digital display.

All of the controls are now sorted and a combined digital speedo and tachometer and rear light have been fitted, so just wiring to go.

The clutch issue is now solved, thanks to lots of mucking about with the sprocket and lift mechanism. The clutch lifter, when operating, moves toward the drive sprocket, with a 10mm offset sprocket and HD 520 chain they met at 1/4 lift.

Another lift mechanism has been sourced from a later model, which sits more flush on the inner case and gives 4mm extra lift, then another 3mm off the back of the sprocket and turned chain link to the inside and all is now fine with more than enough clearance at full lift.

Almost There

Our 1984 Suzuki GSX 400T is almost at the end of its restoration journey.

Although there is still some work to be done, as you can see from the photos below, it’s looking good already.

Almost Up And Running

Our 1984 Suzuki GSX 400T has continued its restoration progress.

The headlamp bracket and the rear lights still need to be sorted and all of the electrics are currently being positioned out of sight.

The tank will be fitted soon. Once this is fitted, it can then be decided where the electrics will go. The tank has been lowered so space is more limited. The bike will also be rewired with a new harness as this will be more time effective than trying to make the existing wiring fit.

A KTM ignition switch that fits the top yoke should be able to be re-purposed so the positions include lights ‘on’. This means that just the starter button, horn button, and dip and main will be on the bars. The bike should be complete in around 10 days, although the exhaust still needs to be fitted up.

The footrests have been positioned 5-6″ further back so, when riding, you can stretch over the bike to get a more comfortable position. The only mechanical work left to do is the exhaust and fit the bodywork, and then the wiring will be finished before the bike gets up and running.

Frame And Engine Progress

More progress has been made on our 1984 Suzuki GSX 400T. The original guard was used instead of a hugger, as the arm was too narrow for this. Before deciding on a guard, huggers from Honda, Yamaha, and Aprillia were tried but they were all designed for cast alloy swing arms meaning they were too wide to be trimmed to fit.

Rear and lower stays have been added to the ally guard and the frame is now being prepped for powder coating.

Stainless allens and flanged bolts have been fitted ready for the engine to be installed. The bolts were taper headed to help improve the finished look of the bike and the new oil filter was fitted too.

GSX 400T Progress

We have recently received an update on the progress of our 1984 Suzuki GSX 400T.

The frame and smaller parts of the bike are being prepped to be powder coated in satin black. The rear loop has been shortened and it now sits under the seat. The rear guard will likely not be used so a hugger may be sourced and modified instead.

Another modification has been made to the swing arm to catch the calliper torque motion on a peg rather than an arm. This will clean up the back end before more brackets are removed to continue the restoration process.

Getting Some Sun

Our 1984 Suzuki GSX 400T was able to enjoy some time in the sun recently. After being in the workshop of JAL Restorations for a while, it has finally been able to be photographed outside in the sunshine!

It’s always exciting to get updates on this special project and we love seeing the bike outside and moving closer to being back out on the road again at some point in the future.

New Shocks For Our Suzuki

The new shocks for our 1984 Suzuki GSX 400T have finally arrived!

To make them fit as they need to, a new upper mount will need to be made on the drive side. The stub to the collar on the frame will need grinding off so it can be drilled out and a new one welded in. On the other side of the bike, a spacer and dome note should be all that is needed.

Progress Images

After the recent progress update that we received from JAL Restorations about our 1984 Suzuki GSX400, we have now received some images of the bike too.

As this is a custom project, the classic motorcycle will continue to change its appearance and transform into the bike that Bridge Classic Cars Director, Craig is looking to build.

GSX400 Progress

Our 1984 Suzuki GSX400 has been with JAL Restorations for a little while now as they work on bringing this classic bike back to life.

While there have been several challenges and obstacles that have come up during the restoration/modification of the classic Suzuki twin, some positive steps in the right direction have been made too. Because of the custom nature of this particular GSX, the swing-arm has been modified and fitted to the bike. This was a lengthy process but, fortunately, the old rollers and bobbins were able to be reused.

9mm had to be removed from each side of the mounting cross-member and a countershaft to hold the bearing bobbins and spacer was required. Custom shims were then fitted on either side to act as grease retainers to make sure that the changes made to the swing-arm and the cross-member work together.

Shocks are currently being sourced now that the swing-arm and cross-member are installed and a seat is also needed. Once the seat has been found, the hoop length can be accurate or a custom build may be required. However, the rear hoop has been modified and is ready to fit.

There’s still a way to go before our 1984 Suzuki GSX400 will be finished but progress continues to be made towards its new future and that is an exciting thing to think about.

Suzuki GSX400 Frame Shortening

Progress is being made on our 1984 Suzuki GSX400. Clinton from Holdsworth Artisan Metalcraft has been commissioned to build this one for us. The bespoke battery tray is now being married up to the simplistic frame work. The rear of the frame has now been cut away and removed to begin the cafe racer style looks to the body.

Clinton is now working on the bracketry for the custom battery box and shaping the rear hoop.

Custom Made Battery Box

Our friend Clinton from Holdsworth Artisan Metalwork has made this custom battery box for Craig’s 1984 Suzuki GSX 400T cafe racer motorbike. Clinton has carefully made this box by hand, bending the metal into shape and welding the corner together.

Modified Suzuki Elements Back At HQ

With the modified fuel tank back at HQ, Craig can begin to fit his 1984 Suzuki GSX 400T back together. The seat frame had also come back and is ready to start being assembled.

Modifications for the Suzuki GSX 400T

Craig’s Suzuki GSX 400T has been pressure tested to check it can withstand the correct pressure with its new modifications.

The seat frame is also being modified so that the curved piece of metal seen below will make up the new smaller seat frame, leaving the majority of the bike exposed for a more rugged and raw dirt bike appeal.

Suzuki Fuel Tank Redesign

Craig’s 1984 Suzuki GSX 400T has had its fuel tank redesigned by Clinton from Holdsworth Artisan Metal Craft. This has been done by reshaping the side panels to allow the rider’s knees to sit more comfortably around the sides. Although this is more of an aesthetic refurbishment, it’s still just as important.

Welcome Back Home

Craig’s Suzuki GSX400 Custom has come back from Demand Engineering where the exhaust was being fitted. It was a tough decision between a short or long exhaust but the choice was made to go for the shorter option.

It is now ready to be reassembled and the rest of the refurbishments made!

Dan’s In Demand!

Our Director Craig has had a bespoke exhaust made for his 1984 Suzuki GSX 400T. The custom-built exhaust is the handy work of the genius Dan Dew from Demand Engineering.

“Dan’s built the whole exhaust” Craig explains “he’s even made the can shorter upon my request.”

A shorter can on the exhaust not only better suits the café racer style Craig’s aiming for, but will also make the bike louder.

If anyone can make a bespoke exhaust and can – Dan can! We’re always super impressed with the craftsmanship from Demand Engineering. This custom-made exhaust is no exception.

The only thing left for this extraordinary build is to get the engine out and blacken the whole thing. Looking forward to hearing that exhaust roar!

1984 Suzuki Tank in Primer

The tank is blasted, repaired, shaped and primed and now awaits the new colour scheme…which is yet to be confirmed.

Refurbishing our Cafe Racer fuel tank

The fuel tank is now going through a full transformation as we remove the badge housing, blast the tank and prepare for paint.

The end result will be a flush, smooth finish in a high gloss colour, TBC.

Making space for the custom exhaust

In order to make way for the custom exhaust, we are temporarily removing the side stand and brackets.

The centre stand will be removed entirely and not replaced but the side stand will be reapplied once the exhaust is in place.

Suzuki GSX400 Custom Exhaust

Before we look to cut the frame, alter the overall appearance to a cafe racer and start to piece together the bike with brand new components, we have taken the basic set up to our very good friends at Demand Engineering. Demand will be the next guys to get their hands on our bike as we look to design and manufacture the bespoke custom exhaust. A very different look to the original with the appearance and sound being absolutely critical to what we want the end results to be. We cannot wait to sit down with Dan and plan the next steps.

Introducing Demand Engineering:

“Demand Engineering makes exhausts, that’s what we do, and that’s all that we do.

We’d like to think that we’re getting pretty good at it, but we’ll let you be the judge of that.

Demand was formed in 2011 by two friends doing what a lot of friends do, finishing a conversation that starts with the immortal lines ‘what if you and I…..?’  they both happened to be Engineers, and they both had passion for all things noisy with wheels on.

Fast forward 7 years and we’ve been involved with some pretty special projects, in a wide variety of vehicles, from GT40 race cars to irreplaceable classics.  We’ve built exhausts for Boats, Bikes, Tractors, Buses, Supercars and even Aeroplanes. That doesn’t mean to say we haven’t done a fair few ‘normal’ cars as well, Subaru’s, VW’s, Fords, and seemingly endless Motor homes.  There’s been nothing I can think of that has phased us.

We work with all of our customers to give them what they want, I’d like to think that was kinda the point.   We’ve worked with Guy Martin on his Transit van, and with Universities with their ‘Formula Student’ cars.
Side exit? No Problem. Lightweight, Carbon fiber Race Kart exhaust? Sure. Needless to say, if it has an engine, we’re bound to be interested!  We can build and create manifolds, silencers, tailpipes and more,  come and have a cup of tea and lets talk about what we can do for you.

Over the years, we’ve also become pretty adept at exhaust development.  We have designed, tested and manufactured exhausts for other companies, from specialist equipment to super cars.  With computer controlled Tube bending equipment, combined with our fixture tables, we can precisely replicate any design, over, and over again.

One thing in common with all that we do, for every exhaust we make, from a tuned equal length manifold, to a rear silencer on a family hatchback, we offer the same level of care and attention, workmanship, materials and customer service.

Demand Attention and Performance.  It’s our name on the exhaust, and we’re proud of what that means.

Suzuki GSX400 New Headlight Design

Huge thank you to Alchemy Motorcycle Parts for their assistance on this design modification. Our 1984 Suzuki GSX400 Cafe Racer/Bobber now has it’s new headlight.

We have been searching the market for a 6 inch LED with black surround and an integrated black mesh front. We have been able to find this specification in a H4 Halagen format or a 7.7 inch size but the size and specification has been tricky to master.

There are plenty of 6 inch LED options but the only grille able to fit would be a retro-fit option that screws to the sides. This was not the look we were going for.

A call to Alchemy Motorcycle Parts and a little homework on their part and they have successfully managed to marry up the LED 6 inch headlight with the integrated mesh used on the Halagen set up.

And it looks amazing…thank you!

Suzuki GSX400 – Temporary Refit

New bearings have arrived from France so Paul has pieced together the bike using the parts we have started to gather.

The re-design is starting to take shape and although still in the early stages, we are really impressed with the look so far.

We will now position the seat so we can assess the frame and reshape where necessary.

It’s a black bits day…

The transformation of our 1984 Suzuki GSX400 is one step further forward today as we painted the metal components in the new satin black finish.

At the same time, we resprayed the repaired dash of our 1973 Triumph TR6, ready for rebuild.

Sandblasting our Suzuki tank

Our 1984 Suzuki GSX400 custom restoration project work has made further progress as we sandblast the existing tank ready for the new Monza style filler cap neck to be welded in prior to the tank being painted in it’s brand new colours.

Suzuki GSX 400 T Engine Blasted

Our Suzuki Engine has recently been blasted in preparation for paint. The heart of this Suzuki will live on when it’s reborn as a cafe racer. The engine will now go over to our paint shop to be painted in heat resistant paint.

More parts arrive for our Suzuki Cafe Racer project

Every day more parts come through the door for our Suzuki GSX 400 Cafe Racer project.

The engine is currently being sandblasted in preparation for painting. The next steps will be painting the fuel tank and engine before fitting all of our new and refurbished parts back onto the Suzukis frame.

Suzuki Cafe Racer strip down

We’ve ordered up a custom rear light strip from New Rage Customs. This will compliment our new ‘Bobber’ style seat and overall minimalistic look.

Paul has completely stripped the Suzuki, in preparation for sandblasting and then later, painting.

The next steps will be to refurbish the forks and the fuel tank.

Then once the frame is painted, we can prepare the entire bike for assembly with new parts.