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.
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.
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.
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.
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.
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!
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.