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Blood Sweat Tears and Grease => Projects => Cafe Racers => Topic started by: Rusnak_322 on May 13, 2017, 18:02:33

Title: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on May 13, 2017, 18:02:33
About time I started a build thread for this bike.

This one is for my wife, she has a vision of what she wants. Happy wife = happy life.

Here is her inspiration

(https://uploads.tapatalk-cdn.com/20170513/1544a86e2335258ff9d9c5c9a650a56c.jpg)

She wants it flat blue tank with tangerine wheels.

(https://uploads.tapatalk-cdn.com/20170513/de5c7abd2c6827c6e899200e59ea3aa2.jpg)


(https://uploads.tapatalk-cdn.com/20170513/3e6669d3df455bea0435c19eaf4a563c.jpg)


Here is the blue that I am thinking of, with a matte clear. I plan to paint it myself.

(https://uploads.tapatalk-cdn.com/20170513/a300516e5e3fa971cbdbb96715141bbe.jpg)

Here is a powdercoat color that we are looking at for the wheels. I wouldn't mind a little orange elsewhere on the bike to tie it in with the wheels, but I can't think of what else to coat.

(https://uploads.tapatalk-cdn.com/20170513/91ea3edd408935bd8f6bf252ad77f6e4.jpg)










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Title: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on May 13, 2017, 18:14:55
This is what we are starting with.
 (https://uploads.tapatalk-cdn.com/20170513/6286747fbddc305033ef1bb3f8afe620.jpg)

(https://uploads.tapatalk-cdn.com/20170513/71310ae7d6132f47030a6dc441109d8e.jpg)


She wanted a disk brake and I think mags will look cool, so I bought a parts bike for $80 and made the swap.

(https://uploads.tapatalk-cdn.com/20170513/a842567d66cde8d24022c692bbeba62e.jpg)

(https://uploads.tapatalk-cdn.com/20170513/f28138269b2ef39c4f942c83981f38ee.jpg)

(https://uploads.tapatalk-cdn.com/20170513/4e2f296e41921d186d29f993a6c19d0c.jpg)

(https://uploads.tapatalk-cdn.com/20170513/c31e0753a198aa230d88ee6f681409c1.jpg)


(https://uploads.tapatalk-cdn.com/20170513/ed221402279f7420fe6c46b261ffda25.jpg)







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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on May 13, 2017, 18:31:12
The plan is for a flat seat with a short rear fender.

(https://uploads.tapatalk-cdn.com/20170513/d5eb7e6f733a4f5664d8da047e6ed904.jpg)(https://uploads.tapatalk-cdn.com/20170513/954fc3cda2086951d222230f51a88665.jpg)

(https://uploads.tapatalk-cdn.com/20170513/a9e79677f8256b5a1b3b85dc569537be.jpg)

(https://uploads.tapatalk-cdn.com/20170513/e5929ebf5de0b129f739665bbe81666e.jpg)

(https://uploads.tapatalk-cdn.com/20170513/d14a716299aab41385c75d4ad1dad71a.jpg)

(https://uploads.tapatalk-cdn.com/20170513/59894941dc3499ce3c1497943e36b383.jpg)

(https://uploads.tapatalk-cdn.com/20170513/f91a3b47f6215d195fb71fbc512627f3.jpg)


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on May 13, 2017, 18:41:12
Cut the frame today.
(https://uploads.tapatalk-cdn.com/20170513/53a940ae22af2666c30335326de5ab40.jpg)

(https://uploads.tapatalk-cdn.com/20170513/d03382b7656284eb6704f195f5d66d67.jpg)

(https://uploads.tapatalk-cdn.com/20170513/1517d019379a70cf3af08109863f528d.jpg)

And making a seat hoop. There isn't a off the shelf hoop that I can find that will work with the XS and its wide hips. It isn't a standard die size for tubing benders. So I made my own.

(https://uploads.tapatalk-cdn.com/20170513/15d0a873934f3466f82bde94291a2bcd.jpg)

(https://uploads.tapatalk-cdn.com/20170513/56287137bafccfaeca461a115765ba8b.jpg)

Used a router table with a 7/8" cove bit

(https://uploads.tapatalk-cdn.com/20170513/7b2e9af3185364df20562d9f09b9459c.jpg)

Glued and bolted together, added a bushing and a strap to hold the tube. (https://uploads.tapatalk-cdn.com/20170513/83d838379e756f85ec362ca438b1999f.jpg)

(https://uploads.tapatalk-cdn.com/20170513/eb3e8712a4ce4051c3a90a595321e66f.jpg)

(https://uploads.tapatalk-cdn.com/20170513/50a971992ea802c506a3270b26c5db1b.jpg)

(https://uploads.tapatalk-cdn.com/20170513/c3e66627b0371e3256437afb59f0ccd4.jpg)






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Title: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on May 13, 2017, 18:42:13
Filled the tube with play sand and welded bolts to the ends.

(https://uploads.tapatalk-cdn.com/20170513/cda4f6d40bd4e7d91b150b51b312ef12.jpg)

(https://uploads.tapatalk-cdn.com/20170513/ad3312edc6d9ca24a61c6e332795bc51.jpg)

(https://uploads.tapatalk-cdn.com/20170513/40f00c5c2a12ad04f287b1d99fd952b8.jpg)

(https://uploads.tapatalk-cdn.com/20170513/871024a6c13dab375299da140a3d9993.jpg)

(https://uploads.tapatalk-cdn.com/20170513/6d6f4038d7431a4907c7df9c33fe38ac.jpg)

(https://uploads.tapatalk-cdn.com/20170513/eedf012a0a3c14fff4f2d1ff4edbe4bb.jpg)

(https://uploads.tapatalk-cdn.com/20170513/af22b3dbad21dc36466bc4f817cf6271.jpg)

That is where I am at. I need to come up with a way to bend the hoop to match the seat.

I also picked up everything we need to convert the rear 16" rim to a disk 18". That will allow better tire selection.

(https://uploads.tapatalk-cdn.com/20170513/e6ca4f6178b626fb53837952e0f6a5f1.jpg)




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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Ant36 on May 13, 2017, 22:04:15
Nice build I like the wooden dies for the homemade bender! Very creative!


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Jun 02, 2017, 18:59:28
Anyone have a newer Ducati Monster? My wife is really wanting to have the Monster headlight on her bike.

(https://uploads.tapatalk-cdn.com/20170602/ad0bbebab39566943904fce1fe14c260.jpg)


I think that it may be too wide. The nearest Ducati dealer is over 1 hr away. I know that the mounting will be difficult, but I think doable as they bolt to the lower triple on the 696.

Has anyone ever come across a similar aftermarket light? A used Ducati light is going for $200-ish on eBay, so they ain't cheap.


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: canyoncarver on Jun 02, 2017, 22:00:31
Nice bender.  Well done.
Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Jun 21, 2017, 21:12:29
Finally got around to finishing the frame hoop bending.

Made a jig to hold it and some buck to bend against.

I got a small crimp, but the way the seat sits, it won't be seen.

If I were to do it again, I would have welded pipe with a ID closer to the tube OD and even though I made the bucks to account for spring back, I guessed too little.


(https://uploads.tapatalk-cdn.com/20170622/d00ae5d57bc65d05ca5940511e563007.jpg)

(https://uploads.tapatalk-cdn.com/20170622/b1a3d10f141f35a0c96f270981a7ff1e.jpg)

(https://uploads.tapatalk-cdn.com/20170622/53582c3e78053e68c8681c54df3edc3a.jpg)

(https://uploads.tapatalk-cdn.com/20170622/fb4cfd1d6597fdc7bde5cbe71029e874.jpg)

(https://uploads.tapatalk-cdn.com/20170622/5358ebd3bd0de68ea52a7c1687e1b640.jpg)


(https://uploads.tapatalk-cdn.com/20170622/1c1ff49f45c1749edab3a18422371767.jpg)


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Jun 21, 2017, 21:34:51
Any idea how to remove the Cush rubbers? I am going to send the wheels off for powder coating

(https://uploads.tapatalk-cdn.com/20170622/4f2c3ad81e71bebbede7d804ce45b0db.jpg)

(https://uploads.tapatalk-cdn.com/20170622/6f94e4f85749adc8ba0112b4a8f73474.jpg)


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Jun 21, 2017, 21:38:37
Also - picked up some tires.
(https://uploads.tapatalk-cdn.com/20170622/f8d9e2ff39dae13e703b2020bd682d8c.jpg)

(https://uploads.tapatalk-cdn.com/20170622/ff785a6b14bf4b7235803956e0a90e00.jpg)

(https://uploads.tapatalk-cdn.com/20170622/1aa3742a8dd12738027ac6569ad9651d.jpg)


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: irk miller on Jun 21, 2017, 22:05:33
Loving the ingenuity, my man.
Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Jun 22, 2017, 13:28:21
Any idea how to remove the Cush rubbers? I am going to send the wheels off for powder coating

(https://uploads.tapatalk-cdn.com/20170622/4f2c3ad81e71bebbede7d804ce45b0db.jpg)

(https://uploads.tapatalk-cdn.com/20170622/6f94e4f85749adc8ba0112b4a8f73474.jpg)


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My research came up with a problem.
Looks like the rubbers are cast into the wheel and there don't seem to be replacements available.

Anyone ever seen this before? Looks like RD parts are too short to work on the XS wheel.




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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: irk miller on Jun 22, 2017, 14:20:32
They remove with heat.  You can see the metal tube the urethan is cast into.  It comes out of the wheel.  Not too hard to recast from a 2-part urethane if you need to.  I converted a rear drum brake wheel to disc by machining a hub to hold the rotor and casting it into the rim with urethane, so it's essentially just like a cush drive.  That said, maybe it's not worth the effort to powder.  You can always use an automotive paint with a 2k epoxy clear coat. 
Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Jun 22, 2017, 20:30:04
Yeah, I am leaning that way. I can paint myself, and the powder quote I got was $125 per wheel. I can pay to have them blasted and but the paint for the cost to powder 1 rim.

Just trying to decide if it should paint B4 or after I mount the tires. I would hate to have it ruined when spooning on the tires.


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: irk miller on Jun 22, 2017, 20:49:01
That's what a deck of cards is for  ;)
(https://s-media-cache-ak0.pinimg.com/originals/90/1c/de/901cdef7633f666eb2d88c70200d008f.jpg)
Title: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Jun 24, 2017, 20:03:21
I made the slugs and tacked it in place. It came out near perfect. I am glad I tried this vs paying someone to do it.

I used a metal stake that is made for concrete forms as the base for the slugs. The frame and hoop are the same OD but different walls, so I spent some time with the angle grinder to make them fit.

(https://uploads.tapatalk-cdn.com/20170624/de3ed35c9b13ad36871083956bc27572.jpg)


(https://uploads.tapatalk-cdn.com/20170624/9a6f8abeac7dfa4f15798b08191f6fe4.jpg)


(https://uploads.tapatalk-cdn.com/20170624/cbea67e8e4122ba16a2bbcb374edb443.jpg)


(https://uploads.tapatalk-cdn.com/20170624/4b03281a927f0e6bac1c1515784a935c.jpg)


(https://uploads.tapatalk-cdn.com/20170624/a34b7d82047bfa75a2b8a62b76c984c1.jpg)





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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Jul 01, 2017, 17:43:17
Got some work done, mounted the fender in place, got in a rear brake master and getting ready to recess the rear brake light into place. Also mocked up how it is going to look with the tires.

(https://uploads.tapatalk-cdn.com/20170701/a1aac92005e9e61dcaccdbcdf680bb20.jpg)

(https://uploads.tapatalk-cdn.com/20170701/f5822bde115c5d196ed96a095cdef32d.jpg)

(https://uploads.tapatalk-cdn.com/20170701/7369cf8171c2d51e29a257b5b1d1bf68.jpg)

(https://uploads.tapatalk-cdn.com/20170701/0351c44129ca3a81d62395e4afaf4428.jpg)

(https://uploads.tapatalk-cdn.com/20170701/cdb30b4d7e39a35f061fb484c890fc7f.jpg)

(https://uploads.tapatalk-cdn.com/20170701/5b10d973cb1f90707fb2fae6afab4c35.jpg)


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: OneOffStroker on Jul 04, 2017, 21:37:35
Any idea how to remove the Cush rubbers? I am going to send the wheels off for powder coating

(https://uploads.tapatalk-cdn.com/20170622/4f2c3ad81e71bebbede7d804ce45b0db.jpg)


I don't know if you have thoroughly made up your mind about painting the wheels or not, but I can tell you that you can leave the rubber in the wheels and have them powdercoated.  I powdercoat and sometimes I get parts that can't have the bushings removed, and I've never had an issue with leaving them in. 

I like the inspiration pic at the beginning of the thread.  It's very similar to what I have in my head for my wife's CB650.
Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Jul 05, 2017, 18:05:33
I don't know, I read a few posts on either xs400.com or the Facebook page about people ruining the wheel. Some did OK, but I can paint them for 1/2 of the cost for powder. I was quoted $125 per rim. I bet I can buy all the paint (primer, base & clear) for that amount.


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Jul 05, 2017, 18:06:26
Plus the wheel bearings look new, so that would save me an additional $30-ish dollars.


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Jul 06, 2017, 11:16:08
Anyone know if you need to upgrade your regulator when installing a Lithium battery if you have a CDI ignition? I read that the Lithium batteries don't like old bikes with higher charging voltage, is there any way to tell what that cut-off is? The bike is a 1980.

thanks,
Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: canyoncarver on Jul 06, 2017, 12:13:05
Anyone know if you need to upgrade your regulator when installing a Lithium battery if you have a CDI ignition? I read that the Lithium batteries don't like old bikes with higher charging voltage, is there any way to tell what that cut-off is? The bike is a 1980.

thanks,

Get a new reg/rec, these old bikes need them.   The old ones are crap. 
Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Jul 06, 2017, 16:46:30
My TO DO list


XS400 to Do:
Cut light into hoop
wheels to get blasted and then powder coated / painted
Weld bracket for rear brake master cylinder
Fix starter
Paint tank
Paint frame
Wiring
Rebuild carbs??
Build battery box and electronic holder


XS400 to Buy:
Tires
Tubes

Wheel bearings – Don’t need if painting
handle Bar / Triple clamp vibration plugs
Speedo
Headlight - $77.31
Front turn signals $12.99

Paint / clear
Engine paint
rear brake master cylinder $9.99
Shocks?
Grips
Battery - $114
Headlight mount - $14.99
Exhaust wrap - $11.80
Mufflers - $59 ea

Front master cylinder / Clutch perch
Brake lines - orange
Fork gaiters
Coils??
Chain??
Plate holder
Oil / filter
Regulator
Tank graphics
Orange plug wires
Mirror
Fuel filter / fuel line
F&R Brake pads???
Air filters???
Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Jul 09, 2017, 11:33:06
Rebuilt the starter motor, turned out to be a big pain. The king bolts holding it together were hard to get off, and then the rebuild kit I bought had way more parts then the starter did. Last, I had a hard time getting the gears to mesh correctly. I didn't know what the problem was, but when I would get it together it wouldn't spin by hand. Finally got it fix, installed and was able to turn the motor over pretty easily.



(https://uploads.tapatalk-cdn.com/20170709/be7d3d22bff6d6e4a07a9120e7352d1e.jpg)

(https://uploads.tapatalk-cdn.com/20170709/d90480b815c3d596c22fec002d649dce.jpg)

(https://uploads.tapatalk-cdn.com/20170709/ccd99d2168cd31cd5dd062b446a478b3.jpg)





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Title: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Jul 09, 2017, 11:36:25
I finally sucked it up and bought a blast cabinet. Got it on Craigslist for $100. It is a Harbor Freight and the reviews on the site said that it took around 4 hours to build, so driving 1 1/2 hours each way to pick it up was worth it.

Tried it out with some 80 grit glass from HF. Works great, wish I would have had it for the last 2 bikes I did. I spent so much time washing, degreasing, and wire wheeling parts to get them ready to paint.

(https://uploads.tapatalk-cdn.com/20170709/daf2da08e415a28b7857f2b125bd4244.jpg)

(https://uploads.tapatalk-cdn.com/20170709/b27cb7c5e22a2abc3cf38711a90df19d.jpg)

(https://uploads.tapatalk-cdn.com/20170709/526d324ebf75ee1764b2848f82ff88bb.jpg)

(https://uploads.tapatalk-cdn.com/20170709/3ce01fc09a93531539cff193f80b5114.jpg)

(https://uploads.tapatalk-cdn.com/20170709/161112e809d9025070959ac343cd8c57.jpg)

(https://uploads.tapatalk-cdn.com/20170709/3140acec73bc1987a8db98c0fb34e215.jpg)



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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Jul 13, 2017, 16:46:36
Got a lot of parts in yesterday.

Headlight. Headlight mount. Mufflers. Exhaust wrap. Small battery.


(https://uploads.tapatalk-cdn.com/20170713/22c5094fe064b99f8555b4b65c406553.jpg)

(https://uploads.tapatalk-cdn.com/20170713/bdb3436d4143e66aaa7ddf09858c1a71.jpg)

Got lots more stuff on order, hope to get the wheels painted and tires mounted as well as pull the motor from the frame to clean and the de-tab the frame and paint.

Get close. Mid Aug is the deadline to get it on the road.


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: vwrabbit on Jul 13, 2017, 22:29:37
Those blasted parts look great.  Did that wheel fit in the cabinet OK? 
Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Jul 13, 2017, 23:18:07
Yes, that is a 18" dia wheel and it fit with plenty of room to move it around. I did need to take it out to flip it.


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: vwrabbit on Jul 13, 2017, 23:48:42
Nice. Going to have to find one of those cabinets.
Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Jul 16, 2017, 20:24:50
Started to build a battery box for under the seat

(https://uploads.tapatalk-cdn.com/20170716/5c9a871229fe5738b9b45dacfc7cd005.jpg)

(https://uploads.tapatalk-cdn.com/20170716/e85fdf45c409eb092ccaa425575063e3.jpg)

(https://uploads.tapatalk-cdn.com/20170716/f1ed82278eac91728a503e9382440bdc.jpg)




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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Jul 16, 2017, 20:26:38
Also pulled the motor and started to degrease to get ready to paint.

(https://uploads.tapatalk-cdn.com/20170716/aed5cdc95d175eb21046c12a26aaca59.jpg)

(https://uploads.tapatalk-cdn.com/20170716/0e28cdb7c598e17bc7d61aa66c78ea7c.jpg)

(https://uploads.tapatalk-cdn.com/20170716/5cf7207dac0587ac795e1a5f0412a0e7.jpg)

(https://uploads.tapatalk-cdn.com/20170716/83e88386db06a443ad799d5b6855c5c0.jpg)


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Jul 21, 2017, 20:14:23
If the rain holds off, I hope to get the paint on the rims.

House of Kolor tangerine kandy.

(https://uploads.tapatalk-cdn.com/20170721/48e1d338b761523e274732d5607ec648.jpg)


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Jul 22, 2017, 18:07:51
(https://uploads.tapatalk-cdn.com/20170722/603afe9f1158858cc0a2ea94319eb6e6.jpg)

(https://uploads.tapatalk-cdn.com/20170722/e62f2fc1a307dcca0f62f1d75ce9c2b6.jpg)

(https://uploads.tapatalk-cdn.com/20170722/c21c740da9a12ebac0dcf6ceeb011a24.jpg)

(https://uploads.tapatalk-cdn.com/20170722/0c413036d590360f17d399577894acf5.jpg)(https://uploads.tapatalk-cdn.com/20170722/51c6bb56e7f01497ff397911b61ff132.jpg)


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Jul 22, 2017, 18:15:26
I hope to get to the tank tomorrow. Doing the prep now.
(https://uploads.tapatalk-cdn.com/20170722/88514bffbfee7b9d8a59da02ce29bba8.jpg)

(https://uploads.tapatalk-cdn.com/20170722/5e5fce36222c5126bd1168cdf48eb461.jpg)




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Title: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Jul 22, 2017, 22:39:34
Also getting some work done on the motor.

What is painted black now is the krinkle paint. The side covers will either be gloss or matte black.

(https://uploads.tapatalk-cdn.com/20170723/be934cb66f569918ac5b6bf0c3928d48.jpg)

(https://uploads.tapatalk-cdn.com/20170723/1603466bd86442a5843a10e9c3719d9a.jpg)

(https://uploads.tapatalk-cdn.com/20170723/c21b235cc936b334a9acf911c67b793e.jpg)

(https://uploads.tapatalk-cdn.com/20170723/1b543af593fc3adcc61367e292d4b944.jpg)

(https://uploads.tapatalk-cdn.com/20170723/999b39d9cc46d6a51568c5362a703b09.jpg)





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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Jul 23, 2017, 17:24:30
Sides are gloss.
(https://uploads.tapatalk-cdn.com/20170723/389e61b124ef73eb510f0dbdd9426936.jpg)

(https://uploads.tapatalk-cdn.com/20170723/f4c0870241b94225aa6fb96a48bc15c2.jpg)

(https://uploads.tapatalk-cdn.com/20170723/3fe150e6b80529ac2e6660599d27f622.jpg)




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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Jul 23, 2017, 17:29:07
Tank is House of Kolor Lapis Blue with a flat clear coat. Looks more semi gloss then matte

(https://uploads.tapatalk-cdn.com/20170723/ced27df9f2928e6736cfbb9e10c9b53b.jpg)

(https://uploads.tapatalk-cdn.com/20170723/03c9085a33444cad2fced27f74cb02ce.jpg)

There will be some gloss black vinyl stripes on the side, either Yamaha like the inspiration pic or some speed blocks

(https://uploads.tapatalk-cdn.com/20170723/bfc406bc318022871d094a8855cb026d.jpg)


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Jul 23, 2017, 18:24:32
Colors together in the sun

(https://uploads.tapatalk-cdn.com/20170723/4ccc9dcafbdee420a4b31785cec0dbbc.jpg)


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Jul 26, 2017, 22:37:42
I started the recessing of the brake light into the seat hoop.

(https://uploads.tapatalk-cdn.com/20170727/162d24dd2236176f251aa67f27547094.jpg)

(https://uploads.tapatalk-cdn.com/20170727/47f71125e9cd85231f47ba5db0bfba0a.jpg)

(https://uploads.tapatalk-cdn.com/20170727/1d59c3253b66505f1f656040ba6f661a.jpg)

(https://uploads.tapatalk-cdn.com/20170727/ee41044d555f1203d6e16324987505a7.jpg)


(https://uploads.tapatalk-cdn.com/20170727/8259a078833e72496c0211867ce8ba02.jpg)

(https://uploads.tapatalk-cdn.com/20170727/500126fd62257f2ce25ce5cb99954763.jpg)

(https://uploads.tapatalk-cdn.com/20170727/6194a8543b58a5d721f0b59fc1da71f8.jpg)(https://uploads.tapatalk-cdn.com/20170727/4f653a26944ae4cab1560e555ff2f2f3.jpg)


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Aug 05, 2017, 23:59:30
Started reassembly. Need this ready for Mod vs Rockers next Saturday.

Here we are at 3:00 today.

(https://uploads.tapatalk-cdn.com/20170806/625a9e2a9ee50c309ce4e435de537bbd.jpg)

Here we are at 4:00

(https://uploads.tapatalk-cdn.com/20170806/4a14db0c4abcbe949edbd16d3feb8d68.jpg)


And by 8:00

(https://uploads.tapatalk-cdn.com/20170806/bf3f8102f77e6ccc5c13e30b0c546735.jpg)


(https://uploads.tapatalk-cdn.com/20170806/2d07cd92e18e8e20e63f80c1d95fbced.jpg)


Light came out great. I used spray foam, then hogged it out with a dremel tool and used some body filler to finish it off and give it a nice surface to stick to.

(https://uploads.tapatalk-cdn.com/20170806/c93b7095e0f736d9f282c88ec35d6573.jpg)


I got a polished bolt kit, I put a lot of the head and starter bolts on before I put the motor in the frame as they are a bitch to get to.

Then later, after the motor is good and in, I remembered that I forgot to use the never seize, so they have to come out again anyway.

(https://uploads.tapatalk-cdn.com/20170806/bf12282fa5751e9e86731d1bfd35669b.jpg)


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Aug 08, 2017, 21:59:55
Got the tires mounted. The exhaust and headlight installed and the bike started.

Still lots to do. Need a chain, have brake lines on order, need to finish wiring and the install the gauge. Also need to relocate the horn and figure out what shocks to get.

(https://uploads.tapatalk-cdn.com/20170809/4e7626234733d3eb838fb0158f690fdd.jpg)

(https://uploads.tapatalk-cdn.com/20170809/27946440f84188f915ff31d59ceb73e3.jpg)

(https://uploads.tapatalk-cdn.com/20170809/0f0af65b157f3499b1547009fe18ed0b.jpg)


(https://uploads.tapatalk-cdn.com/20170809/9539d00d2dc2d2c99a0fb67e32f8e262.jpg)




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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Aug 08, 2017, 22:03:31
(https://uploads.tapatalk-cdn.com/20170809/30145f0ce48571de80d4f09b15f798f4.jpg)

(https://uploads.tapatalk-cdn.com/20170809/13ccb45e42854afc4db68320c2494c09.jpg)

(https://uploads.tapatalk-cdn.com/20170809/f65105332797b562d47c09686d54bc5f.jpg)

(https://uploads.tapatalk-cdn.com/20170809/cd7d3264db1fa96960312111ef624f86.jpg)

(https://uploads.tapatalk-cdn.com/20170809/5c14c13914f22e3f6639adfd1f6f1ce0.jpg)

(https://uploads.tapatalk-cdn.com/20170809/19757834bd90722dc00fb61ac6741c95.jpg)

(https://uploads.tapatalk-cdn.com/20170809/ee9e2bb451bfad07eb1a9059a65ed374.jpg)

(https://uploads.tapatalk-cdn.com/20170809/164190eb2567bf918ec047438cdbcb61.jpg)


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: advCo on Aug 08, 2017, 23:09:34
You know I wasn't sold on the colors, but now that it's assembled it looks great. Nice work.
Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Aug 09, 2017, 22:45:30
Thanks, I wasn't a big fan of the tangerine wheels before we painted them, I wanted a brighter orange. But I like how it turned out.

I got the pipes wrapped and the trail tech gauge installed.

I have some wiring issues, the brake, tail and turn signals are wacky and the bike won't start on the button, just clicks. I had another starter solenoid and that does the same. I can't get the starter to run anymore, even when hooked up to the car battery.

I just rebuilt the starter and it was working fine.

Also, clutch is wonky, I have been playing with the adjuster under the sprocket cover but think that I need to rerun the cable.

Bike starts on first kick and ideals nice. I hope the brake lines come in tomorrow so I can ride!



(https://uploads.tapatalk-cdn.com/20170810/fa8f5be1831ef175ba3a6de4257f9a39.jpg)

(https://uploads.tapatalk-cdn.com/20170810/5105e7c78ca6fa5af706616f609b037f.jpg)

(https://uploads.tapatalk-cdn.com/20170810/29d785a0d27921adb2ec4d688de1f050.jpg)


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Aug 10, 2017, 09:46:24
Inspiration vs reality



(https://uploads.tapatalk-cdn.com/20170810/a77a043d5a7dcac9a7b827f89c4f72a9.jpg)

(https://uploads.tapatalk-cdn.com/20170810/58ec6f86475d144447d0dd1a5f6265d3.jpg)


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Double7z on Aug 10, 2017, 22:44:54
Filled the tube with play sand and welded bolts to the ends.

(https://uploads.tapatalk-cdn.com/20170513/cda4f6d40bd4e7d91b150b51b312ef12.jpg)

(https://uploads.tapatalk-cdn.com/20170513/ad3312edc6d9ca24a61c6e332795bc51.jpg)

(https://uploads.tapatalk-cdn.com/20170513/40f00c5c2a12ad04f287b1d99fd952b8.jpg)

(https://uploads.tapatalk-cdn.com/20170513/871024a6c13dab375299da140a3d9993.jpg)

(https://uploads.tapatalk-cdn.com/20170513/6d6f4038d7431a4907c7df9c33fe38ac.jpg)

(https://uploads.tapatalk-cdn.com/20170513/eedf012a0a3c14fff4f2d1ff4edbe4bb.jpg)

(https://uploads.tapatalk-cdn.com/20170513/af22b3dbad21dc36466bc4f817cf6271.jpg)

That is where I am at. I need to come up with a way to bend the hoop to match the seat.

I also picked up everything we need to convert the rear 16" rim to a disk 18". That will allow better tire selection.

(https://uploads.tapatalk-cdn.com/20170513/e6ca4f6178b626fb53837952e0f6a5f1.jpg)




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Could you tell me more about this process. I want to have 18 inch wheels with disc brakes on my xs400. Where did you get the 18 inch mag for the rear set up?

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Title: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Aug 10, 2017, 23:17:12
eBay.
I found a seller with a rear wheel and all the other parts. He was parting bikes out and had everything for sale separately. He was asking crazy prices, like $9.99 just for rotor bolts. I sent him a question and offered to buy all of it for one price.

I think I paid $120 with shipping. I got the wheel, swingarm, caliper, caliper hanger,  two sets of the thing that the brake lever mounts to, a rotor, brake pads, axel and spacers, sprocket and just about all the hardware that I needed.

I bought a master cylinder that is for a dirt bike with no reservoir ($10 eBay new) and welded a bracket to the frame to mount it. I cut up some square tube that I got from Lowes for that. The I ordered a custom brake line ($70).

We didn't need a disk rear, but my wife wanted a disk front and the 18" rim allowed better choices of tires. I couldn't find a 18" front / 16" rear tire set that I liked. The other option would have been to lace up a 18" rim to the spoked rims that came with the bike and make another disk hub spokes rim fork for the front.




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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Aug 13, 2017, 10:00:17
Well the plan was to have it for Cleveland Mods vs Rockers yesterday. I got the bike done for my wife, but the ride ended early when the battery wasn't charging. I swapped out the rectifier and regulator but that didn't help. I need to look to see how to check to make sure that they are working and to check the stator. Any links to places that walk a dummy through that?

I had did research on the  Shorai battery, I thought that they were OK with the older rec/regs. I may need to buy a combo unit any recommendations?

(https://uploads.tapatalk-cdn.com/20170813/d85f1fbf9e95c475bcde885616a93937.jpg)

(https://uploads.tapatalk-cdn.com/20170813/32a2e2d648329338042e747dfca56149.jpg)

(https://uploads.tapatalk-cdn.com/20170813/8e4f81ed3d180b32147349c295416e89.jpg)


(https://uploads.tapatalk-cdn.com/20170813/8ee795508dd2c70bda896d5cf8354ee4.jpg)

(https://uploads.tapatalk-cdn.com/20170813/9f46d80c43096242096a86c3e8652453.jpg)

(https://uploads.tapatalk-cdn.com/20170813/368d0e0890f14a44f051c1234d7452e4.jpg)

(https://uploads.tapatalk-cdn.com/20170813/c21413bec08c826ed1eb1a24fc16c97f.jpg)

We still went to the bike show, she just had to ride her Ducati. Kinda hard to feel too bad about that.


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Aug 17, 2017, 10:08:18
Here are some detail pics I took.
Ignore the wiring mess, I have charging issues.

(https://uploads.tapatalk-cdn.com/20170817/8139b1beed731b7c43e1c9eebc3b7616.jpg)

(https://uploads.tapatalk-cdn.com/20170817/7cddc1d2323238fc723a81c583b3f34c.jpg)

(https://uploads.tapatalk-cdn.com/20170817/93cb53af474b8f1a78a2c10bc1ea0973.jpg)

(https://uploads.tapatalk-cdn.com/20170817/1ba1fac1495b26ce004aa8310178a5d2.jpg)


(https://uploads.tapatalk-cdn.com/20170817/8f97bc2e5518c43f7b46c0d55e8d43a6.jpg)

(https://uploads.tapatalk-cdn.com/20170817/b7978eb129f9f566439fc79628a4caa9.jpg)

(https://uploads.tapatalk-cdn.com/20170817/ca650189c9d1211a95f51d2f6b5b5462.jpg)


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Aug 17, 2017, 10:12:55
Think this may be the cause of the charging system to suddenly stop working?

(https://uploads.tapatalk-cdn.com/20170817/bcb8d48bc9d15b02fdb0b3d861dae3d8.jpg)

The three wires coming out of the stator got pinched when I reinstalled the sprocket cover. There was bare wire showing on all three wires and touching the case.

I wrapped with electrical tape to test, but I need to figure a permanent fix.


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Kolby198 on Aug 17, 2017, 12:52:40
Such a good idea to use the ladder to hold up the bike. Going to put that one in my book.


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Aug 20, 2017, 23:41:31
How do you Think this happened???

I have been having a hell of a time getting the clutch adjusted. I read the manuals (Factory and Haynes) and followed the procedures.

This is my push rod.


(https://uploads.tapatalk-cdn.com/20170821/efc327ef467486e34f73bca8eff99bcb.jpg)

Luckily I have a spare parts bike. Here is that ones clutch push rod.

(https://uploads.tapatalk-cdn.com/20170821/ee5cd2b802fb70c72127ef1092c1d8da.jpg)


The stupid thing snapped. Where it broke is so clean that I thought that it was supposed to be that way.

(https://uploads.tapatalk-cdn.com/20170821/c5d2eaef71edb77b7d3a81be0f13737b.jpg)


(https://uploads.tapatalk-cdn.com/20170821/aaa1191c0c95c9359df3efd690265515.jpg)


(https://uploads.tapatalk-cdn.com/20170821/774d0c30ae11dae4d5593d9d7701d861.png)

Had to take the clutch apart to get it out.

(https://uploads.tapatalk-cdn.com/20170821/94086acdda34c0a2c411674c22dfefdc.jpg)

But the clutch still isn't quite right. Yes, the ball is in there.





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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Aug 22, 2017, 20:56:48
(https://uploads.tapatalk-cdn.com/20170822/e0f4873a307ad64af028432b7bf5ad89.jpg)


So I got it going, should I be worried that when running I get 13.5 volts at the battery no matter if at idle or reving the motor?

The light is bright and doesn't change with revs.

Note: this is a lithium battery.

Thanks



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Title: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Aug 23, 2017, 20:14:13
Took it on a 10-ish mile ride today. The speedo sensor wire rubbed the disk and cut the wire, so I don't have a total mileage.

Bike ran great, carbb'ed clean even with what I assume are stock jets. I left the jetting alone until I am able to see how it runs, I bought a few different size main jets to play with. The pipes have very open ( and a little too loud) end cans and I am running pod filters. It was a lot cooler then it has been - 76 degrees or so.

My wife has only ran it to the gas station and around the development so far. We plan to take it to bike night tomorrow. She is excited to the Distinguished Gentleman's Ride this year.

(https://uploads.tapatalk-cdn.com/20170823/1308db287c54f0706c8ed6b7517bdb82.jpg)


(https://uploads.tapatalk-cdn.com/20170823/fb23cf354459661ab399a5a0bc2db523.jpg)


(https://uploads.tapatalk-cdn.com/20170823/f7778db242a7bee0cacd8927891c35ea.jpg)


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Aug 23, 2017, 21:33:20
(https://uploads.tapatalk-cdn.com/20170824/51f25e79151b160548e62d455486fbf9.jpg)

(https://uploads.tapatalk-cdn.com/20170824/78a8ae7c4792b2c4a67c6ad46c4fec03.jpg)

(https://uploads.tapatalk-cdn.com/20170824/fc9687de39da64581f7e118cebf350a6.jpg)

(https://uploads.tapatalk-cdn.com/20170824/f4611acccc36ff3a45483c5a487f944b.jpg)


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Aug 29, 2017, 22:53:40
Trying to come up with a graphic on the sides of the tank. I wanted speed locks with YAMAHA in it but  y wife didn't like it as the right side has Yamaha with a a towards the front of the bike and she didn't like it as much.

Thinking of something like this, but with a larger tuning fork.

Anyone have a better idea or criticism?

(https://uploads.tapatalk-cdn.com/20170830/1753f69727fcbee32cb482e4b974b780.jpg)


(https://uploads.tapatalk-cdn.com/20170830/5b150c7d06a03e4c2847630d6c73d4ff.jpg)


(https://uploads.tapatalk-cdn.com/20170830/105eea0c184df5704c2cdb76f9dfedb6.jpg)


Btw it looks better on the bike then in the pics. I used some matte black vinyl.




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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: 1fasgsxr on Aug 30, 2017, 13:14:29
Do the stripes in white?
Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: 1fasgsxr on Aug 30, 2017, 13:19:23
or keep them black and pin stripe them in the red of the wheels
Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: CQ Custom Designs on Aug 30, 2017, 13:54:38
Just a suggestion what if you moved the tuning forks more towards the top left and not in the black section just right on the blue


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Globe on Sep 03, 2017, 04:35:47
Hi mate, how did you mount the rear fender? I can see the little brackets to the cross frame but I assume there must be another attachment point somewhere and can't see it. Cheers
Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Sep 03, 2017, 08:32:28
There is a bolt that attaches to the seat hoop from the underneath. When I cut the slot in the hoop for the brake light, I welded a nut inside the hoop.

I had tapped the hole before that, but I figured it was simple to put a nut there, and it gives more threads to hold tighter.


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Sep 04, 2017, 22:59:11
Here are some pics from today's ride. My wife wanted to get a picture against a mural.

(https://uploads.tapatalk-cdn.com/20170905/ede5aa8092d4bceb77d4a8d44c91ae7e.jpg)

(https://uploads.tapatalk-cdn.com/20170905/06ff120e7731916ec4fd1796372b3d23.jpg)

(https://uploads.tapatalk-cdn.com/20170905/827f8e1039fa5115bbea89b92d2efef3.jpg)

(https://uploads.tapatalk-cdn.com/20170905/261ae3c374794ff3a086591947b53d25.jpg)


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Sep 10, 2017, 14:19:38
I am having an issue with the idle on my xs400.
Carbs have pods, runs great. But the idle is sometimes perfect and then sometimes way too high. Riding it, it can be perfect at a stop light and then jump way up at the next light and back to perfect again.

Throttle cable is routed correctly and lubed. Carb linkage looks good. Manually closing the throttle doesn't change anything.

Carb manifolds have cracks but spraying starting fluid doesn't change the idle so I don't think that is an issue.

Any other ideas?

(https://uploads.tapatalk-cdn.com/20170910/5da9b15917c3996ab82eaab320e14a31.jpg)


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Sep 15, 2017, 19:33:10
Got some new shocks, 1" longer than stock.

(https://uploads.tapatalk-cdn.com/20170915/41cf2ec9e380c4b1d4c84624e7330a15.jpg)


(https://uploads.tapatalk-cdn.com/20170915/bf16c08eb405f5fa23b66e95d3b21146.jpg)


(https://uploads.tapatalk-cdn.com/20170915/8285eb5302ec85829ba08f39e15223e0.jpg)


(https://uploads.tapatalk-cdn.com/20170915/20d8673898ff16ab1e45ead342cbdbef.jpg)


(https://uploads.tapatalk-cdn.com/20170915/18470a882d1277902d172978eb7b5354.jpg)


Had them on my old CB360 and they worked fine

(https://uploads.tapatalk-cdn.com/20170915/97022b0480182297d40df1243f6a69ba.jpg)


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Sep 23, 2017, 13:00:46
So I ordered a new Motion Pro clutch cable and that mad a huge difference to the clutch action. It is about 4" shorter than the other 2 that I have, fits perfect with the lower superbike bar bend that I have. The bike ( and the parts bike) both had buckhorn style tall bars.

We are all set for the DGR ride tomorrow. My wife I eager to show her new bike off. My Moto Guzzi is all clean and ready to ride as well. It looks to be a hot one, 90 degrees with high humidity. This is the only time we are not ATGATT, so at least it won't be cold and wet.
Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Sep 23, 2017, 17:31:12
Had a little weirdness go on with my exhaust wrap. The fist time I started the bike and let it warm up to “cook” the wrap, it smoked like usual. But this one section turned white.

I had put it on dry.

(https://uploads.tapatalk-cdn.com/20170923/0e18403cb6949b2331750d4dd49b824d.heic)


I have enough leftover to redo the one header, but it is hot out and I don’t feel like getting all itchy.

Busted out the MAGNUM Sharpie

(https://uploads.tapatalk-cdn.com/20170923/a0cafac023302cc4453bbc2876b0aed2.heic)

Found it works best if you put the ink on your finger and rubbed it in

(https://uploads.tapatalk-cdn.com/20170923/7e2d67f0300156f93322881aeb908b65.heic)

(https://uploads.tapatalk-cdn.com/20170923/2caf32429044c2247d7e4a4bba2bc6fa.heic)


(https://uploads.tapatalk-cdn.com/20170923/abdc5632043680562a90338d04138a5d.heic)


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Title: Re: Excess Four Hundred (XS400 Brat Build)
Post by: Rusnak_322 on Sep 24, 2017, 19:03:46
DGR Cleveland today -

(https://uploads.tapatalk-cdn.com/20170924/329b641ec1bf7c7173fd1d49d6db26c7.jpg)

(https://uploads.tapatalk-cdn.com/20170924/de2a5058496c2df1413e22fbd495723e.jpg)


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