1980 RD 400G workshop Manual Question

[604Paulb]

Afternoon All,

I just purchased an RD400G According to the frame # apologies if this has been answered elsewhere in the forum. I can't find mention of a G workshop manual and I'm in need. Would like to restore this bike to its former glory and the engine (3J7 cases) is points. So lots to do and learn. Any advice would be welcome.
Thanks

[SoCal250]

Welcome and congrats on the new bike. Post up some photos!
The 400G is a Canadian spec bike, and is basically the same as the Canadian F model (only the graphics are different if I recall correctly). It should not have a points ignition because the RD400F/G in Canada came from the factory with CDI.
Sorry, I can't help you with a service manual as that model is one of the few I don't have.

3J7- is correct for an F or G mode1. Both were painted New Pearl White, but graphics differ between the years.
F model frame/engine numbers start with 3J7-000101, and G models begin at 3J7-020101
Cylinder head is 1-piece and a 3J7 part
Carburetors and cylinders are 2R9 parts
Wheels and brake calipers are 2V0 parts

[604Paulb]

Thanks for the info SoCal250, I will snap a few pics and upload them. From what I have read, I'm missing the usual hard to find items.
Undertail assembly
Side covers
Tool Kit
Correct Kickstarter.
3J7 casing is damaged. It looks like the chain jumped the sprocket
Exhaust pipes & carbs aren't original.

Looking forward to it!

[SoCal250]

Side covers - are the same as the US and CAN RD400F, just different decals.
Tool Kit - a correct OEM tool kit will be hard to find and very expensive. If you just want a similar universal kit you can get one from Economy Cycle (who sponsors this site) https://www.economycycle.com/product-category/tools-hardware/tool-kits/  Yambits in the UK also sells tool kits. https://yambits.co.uk/tool_kits_parts_for_yamaha_rd400g.html
Kick start Lever - reproduction levers are available from several sources. https://yambits.co.uk/rd400g-kickstart-lever-p-37969.html  The same part was used on the US & CAN RD400F. There's a used on on eBay right now: https://www.ebay.com/itm/176355883141

Here's what yours looked like when new.


There was one for sale here locally a few years ago. Kind of unusual to see a Canadian bike for sale in Southern California.
https://www.2strokeworld.net/forum/index.php?topic=318.0

[604Paulb]

Here's a before picture or two
Lots to do and catalog before digging the wallet out

[SoCal250]

Interesting. Looks like someone has made some changes to it over the years.
The tank and front fender appear to be from a RD400F.
The front end looks like it's from a '76-77 model. (You can measure to be sure but those look like 34mm forks, not the 35mm used on the F/G models).
The front wheel is from a '76-77 model and the rear wheel looks like it's from a '78 model.
The brake rotors are '76-78 versions.
The front and rear brake calipers are pre-79. And the one on the rear looks like it was a front one at one point in time based on the badge clocking.
The swingarm is also not from a F or G model, but a '76-78 RD400.
The kickstart lever is from a '76-78 model.
The round Yamaha badge on the left engine cover is not from a RD400 but a RD250/RD350.

[604Paulb]

I got the impression when I was looking at it that there were a lot of bits that were scavenged. You have pointed out lots I didn't know about so thanks a lot for the input and keen eye!