XS400 café/tracker/scrambler

offroadjeepin

New Member
Figured i might fit in a bit better over here. Switching from a different site.

I've had this 81 XS400 for about two and a half years. When I purchased it was running pretty rough. Determined that is was the very crappy air filters and knew i was going to do custom exhaust and would need jetting. So I tore it down......there it sat for 2 years......i got the itch to finish the it about a month ago.

Yo bring you up to speed. I've worked out the tail section which will utilize a honda grom LED tail light that gets mounted to the underside of the tail. I then started on the exhaust this was my first time working with mandrel bent tubing. Its super easy to work with. Results are a 2 into 1 header with a CR250F left side dual muffler mounted underneath. I've been trying to figure out the shocks. The dual setup really takes from the tracker feel. So I've decided to mono shock it. Im currently trying to get my hands on a Buell XB shock. I placed an order with J-Rod10 for his universal rear sets today. Can't wait to get my hands on them. Well heres a few pictures and a video of some of the exhaust build.

Enjoy!
 

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Thanks! Tubing is from www.mandrelbends.com great selection of tube. I used 1.25" for the front and the last 90 to the muffler is 1.380"
 
Glad you guys are liking the build. We came to an agreement on the price of the XB shock. So in the meantime I will be finishing the exhaust. I have a few collars to turn on the lathe then get the wrap on. Any of you guys installed exhaust wrap? Do I need to paint the bare steel tubes first? Was planning on some ceramic high temp paint down first then the wrap. I got Ti wrap. Do they sell a clear coat for the wrap? I see black....
 
I am doing a XS400 for my wife now.

Yes, you have to paint the header, one of the things about wrap is that it holds water against the pipes. If you have run the bike, the heat will burn it off, but even some high temp engine paint would be better than nothing.

I did the ti wrap on my bike. It was a lot easier then I expected. I did them on the bike, as it allowed me to pull it tight.

They also make a tool to tighten the stainless tie wraps, it also worked really well and was under $10.
 
Yeah, that is the tool I used.
I did it dry, that is what was recommended by the manufacturer. I started at the head, but I read that if you go the other way, the water will run down the wrap spiral and not go in to the pipe. My pipes we crappy looking chrome that I don't really care about, which is why I went with wrap.


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Well not much of an update but here are some more pics of the exhaust. Header collars i turned from a solid on the lathe. Missed a dimension so i turned a small collar to bring the OD up a bit for the flange. I don't claim to be the best TIG welder but they will hold.

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Not much of an update again but made some small progress. Started turning bungs to weld onto frame for rear-sets. Got the swingarm hoop bent. Also ordered some goodies. Progressive front springs, tapered roller stem bearings. Got a CB160 headlight off Ebay. That will be getting a custom mount for a trail tech vapor from a member.

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Another small update. Got the hoop welded on still needs side supports and shock mount. Got the forks pulled apart . Got the new spring in one of them and filled with oil. But I'm not sure I have the correct amount of fluid in them it seems like they come out of the oil when extended....

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Got the stem bearings replaced. Loose ball to tapered. Its soooo smooth now. Also made a steering stop since it didn't have one....... there's a factory stop welded to frame on the top and the tabs are on tbe bottom triple clamp. PO had welded on very riskey piece of square stock with a allen bolt sticking out of one side. There wasnt much steering and it steered farther one way than the other. Anyway all fixed.

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