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Author Topic: XS 400 Maxim: To be or not to be..  (Read 1363 times)

Offline David_W

  • Posts: 48
XS 400 Maxim: To be or not to be..
« on: May 25, 2016, 21:22:29 »
Meet the Maxim:



Recently got it and struggled with what to do to it. Rode it some and decided to embark on a cafe racer build for it. I've been waiting for things to be delivered, and they've finally made it!


KZ650 tank


Universal "cafe racer" seat from across the big pond. I know... I'm not expecting much, but I do like the looks of it.

When I get the issues with getting all of that on the bike (changes to the subframe, etc) I'm going to be getting clipons-maybe, tail light, turn signals, and new brackets for a headlight...all that jazz. Probably a head light too.. We'll see. Maybe rearsets. I want to switch the shift pattern so it matches my race bike. We'll see how tight the riding position is with that though.

As far as mechanics the bike is running fine (for now) more on that in a second.. I've serviced the forks, changed the brake pads and fluid-cleaned the caliper, etc. I plan to run pods because I think it looks a lot cleaner than the air box, and to put it shortly I just want to. Once I get things situated I'll be doing a wiring "spring cleaning" with my dad. He's a wizard with this stuff.

So I've done some "mock-up" if you want to call it that..


Obviously have some kinks to work out, but the general idea is there. Quick aside.. The tank is SUPPOSEDLY the only year that they made that color combo.. It's in pretty good shape.. Should I avoid stripping it and painting/eventually knee-denting it? I thought it would have a longer wheel base than that.. Looks kinda quirky

Any how.. Here is the first kink:


I'm about to go see if I can simply switch out the petcocks... Hope springs eternal right? They valves are in similar positions, however the maxim tank's valve is slightly more forward. With that being said the horizontal piece on the KZ tank that is hitting the frame is in a vertical position on the maxim tank. Probably sound like a raving idiot thinking this could possibly work, but whatever.

Once I get the tank squared away I'm going to look into making a bracket to slightly pick up the rear in an effort to straighten out the top lines. I want to allow the tank and seat to flow so any adjustments to that will be minor.

Next post. Addressing the "running good for now" statement...


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Offline Rusnak_322

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Re: XS 400 Maxim: To be or not to be..
« Reply #1 on: May 25, 2016, 22:41:27 »
That new tank looks way better then the old one. I can't tell in the pictures, but it looks like there may be some dents in It? If that is the case and the tank is not near mint, then there is no reason to save it if you want something different.

Need to figure out how to get the tank and seat to match up and sit horizontal. Any plans? Is the seat wide enough to fit the Yamaha hips on the subframe?



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Offline David_W

  • Posts: 48
Re: XS 400 Maxim: To be or not to be..
« Reply #2 on: May 25, 2016, 23:22:38 »
I got home late last night from work and other work related functions and when I walked into the garage it smelled like I was inside of a gas tank. SO me and my dad searched and searched for the culprit hoping a gas can had leaked or the new (KZ) tank simply smelled terrible. We concluded that it was coming from the Maxim. Specifically the carbs and airbox. We took the cover off and looked at the air filter and it was pretty much black with oil. Exponentially more so than when I checked it about a week before. It also seemed like the swingarm had some serious residue on it. The only thing that I can figure is that a float is stuck in one of the carbs and its flooding back into the air box. Is that possible?
This is what I'm talking about:


So this is the right hand side of the bike looking on from the rear tire.



This is the other side looking into the airbox and you can see where the swingarm connects to the rest of the bike. It's covered in what looks like oil, but it isn't oil. ️ I'm stumped.


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Offline David_W

  • Posts: 48
Re: XS 400 Maxim: To be or not to be..
« Reply #3 on: May 25, 2016, 23:50:22 »

That new tank looks way better then the old one. I can't tell in the pictures, but it looks like there may be some dents in It? If that is the case and the tank is not near mint, then there is no reason to save it if you want something different.

Need to figure out how to get the tank and seat to match up and sit horizontal. Any plans? Is the seat wide enough to fit the Yamaha hips on the subframe?



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Thanks! I think it looks much better. I took the fuel valve off and it sat almost exactly how I planned. After getting clearance issues with the fuel valve sorted the issue will be getting a bracket made to mount it to the frame closely to how the stock tank did.

The Yamaha hips are really something. It's super close with the seat. I'm going to do some more measurements and mockups, but I think if I can get the subframe flattened out and a hoop measures to fit the seat pan I think it'll fit nicely. The brackets on the stock subframe are really what are making the seat pitch down. The real challenge there is going to be where the tank and seat meet.


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Offline David_W

  • Posts: 48
Re: XS 400 Maxim: To be or not to be..
« Reply #4 on: May 26, 2016, 00:04:44 »
Ok quick valve update. SURPRISE! The Maxim fuel valve won't work at all. I'm toying with the idea of either relocating the petcock farther up the tank or just running a valve that I manually turn on and off. I'd rather move the petcock up, but that's going to be difficult and involved. The area that the fuel valve is located seems to be reinforced much more so than any other area along the bottom of the tank.

Here's a picture:
 

Jumping way ahead on the check list.. I think a mix between a gun metal grey and Sebring silver would look nice with the coffee colored seat that I have.


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Offline David_W

  • Posts: 48
Re: XS 400 Maxim: To be or not to be..
« Reply #5 on: Jun 19, 2016, 00:50:26 »
So I've been busy with studying for the GMAT and work lately, but I haven't forgotten about my Maxim! I have a couple of updates too.

http://www.dotheton.com/forum/index.php?topic=70433.msg826305#msg826305
Here is where I was considering ways around the tank issue. I'm going to be taking the tank to a guy Monday and I'll see what he thinks about grafting in the fuel valve area from the maxim tank onto the kz tank and sealing up the holes left from where the stock kz valve was. That way we can use the petcock that came stock on the bike and I know for a fact it works.

Beyond that I've gotten my gauges, new headlight brackets, clipons, signals, and brake light. We ran into issues right from the start. For starters, lowering the controls by almost six inches really put some strain on the brake line and clutch cable. The master cylinder, levers and headlight/turn signals are all vying for the same spot. Gotta figure out how to reroute some of that. The "universal" cheap amazon headlight brackets were a bear. Universal must really mean, "universally fits nothing."

Any tips on where to get shortened brake lines for a Maxim 400? I'm assuming they'd be the same as the XS400. Is that plausible? I thought I remembered seeing on xjbikes that they were few and far between.


I'll update with some pictures tomorrow! It's looking VERY different.
I still need to do some polishing on the motor, especially the side covers. Since the bike is running just fine I think I'll be tearing it down and polishing/powdering everything this fall/winter. I would really like to have it ready for riding soon so that I can enjoy it with my folks.

Offline David_W

  • Posts: 48
Re: XS 400 Maxim: To be or not to be..
« Reply #6 on: Jun 19, 2016, 14:36:50 »


The lighting is bad, but being Father's Day this is the only chance I'll have of getting pictures today.







We have a lot of work to do still. Re working some of the wiring, rerouting some cables, new brake lines. I'm considering a smaller headlight to allow room for everything as that is the stock 7" one. I like that light, but it is taking up a bunch of room..

Once the tank is squared away we'll make the necessary changes to the subframe to finish up the seat. It almost bolts right up to the stock mounts, which I am eternally grateful for. Next I'll have to figure out where to put my license plate..


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Offline David_W

  • Posts: 48
Re: XS 400 Maxim: To be or not to be..
« Reply #7 on: Jun 20, 2016, 15:27:24 »
Just dropped the gas tanks off for the local machine shop to work some magic. He didn't look too enthused, but said he would get it done for me. Things are coming together


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Offline Rusnak_322

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Re: XS 400 Maxim: To be or not to be..
« Reply #8 on: Jun 20, 2016, 15:42:58 »
for brake lines, I used these guys a few times in the past and have been very happy with them.

just tell them what you want and they will make it up for you.

https://spieglerusa.com/brakes/brake-lines-accessories-tools/custom-brake-lines.html

Offline Rusnak_322

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Re: XS 400 Maxim: To be or not to be..
« Reply #9 on: Jun 20, 2016, 15:45:36 »
BTW: that tank and seat look so much better now that you have them sitting flat.  How is the feel of the bike with those low bars and café seat? any plans for rear sets?