Well, my hands smell like oil (when don't they?) and my pants are covered in grime. Just spent the evening tearing down the XS400. Got the engine out of the frame. Man this thing is LIGHT compared to the XS650!!!! Easily done all by myself, whereas the 650 was a chore with two people. This engine is built smartly. Easy to take apart compared to the 650. I noticed a few weeks ago as I was polishing up a few parts on the engine that one of the cylinders didn't have that much compression. So, I tore the top end apart tonight and found that when it was sitting in the back 40 of the PO's, one of the valves was open. Yeah, rings were seized in the grooves, middle ring was cracked. No wonder there's no compression. Cylinder wall has a little crud on it, but its not rusty or pitted. Haven't checked valves/seats yet, but thats next on the list of things to look at. New valves are cheap. Ring set is just over $50. Found another 400 on Kijiji in the GTA for a decent price. Might pick it up if it has a title. This should be a good little project, hopefully done this fall, but otherwise for the spring. Can't wait to unleash that 6 speed transmission! Now, if I can only figure out how to post pictures........
Project Odin - XS400F
- Thread starter rudy
- Start date
Re: 79 XS400
Well, I did it again. Found another bike.... well, same bike, 79 XS400 in blue. Came with a black tank in good condition, and the original tank in blue. HUGE freakin dent in the right side. Looks like the handlebars went THROUGH the side of the tank at one time. Someone patched it up with a welder and put 2 inches of bondo over it. Bars were heated up and bent back, can see the discolouration. Other than that, bike is in decent shape. Only 7300 on the clock, great compression on the kicker. Mine for $350, $40 gas in my buddy's truck, and a couple hours heading to Oakville and back.
Progress so far
She's all tore down already. Already have the ol' wheels spinning in my head about what colours and what to put on it. British Racing Green with Creamy White accents (sorry, flat black is too boring for me
). Should look really sharp...... at least it does in my minds eye. Gonna keep the cast wheels too. Clean up all the casting marks and smooth them out, paint them body and accent colour. Black = Green, Aluminum = White. Gonna lower the front end and put clip-ons above the top tree so they will still clear the stock tank just fine. Gotta do something with the back part of the frame, but I guess I need a seat first. Thinking of making my own outta FG.
Exhaust
I'm kinda undecided on the exhaust still. Was originally thinking about doing something like ProTeal's 450 with it up the side, but I checked it out today and I don't think there will be enough room for two hot pipes there. So, the next idea was straight under the frame and engine. Well, this won't work with the front end lowered, I'll be hitting them pipes on everything. I don't really want to go with stock location, but I'm running out of options. Any suggestions? I'm leaning towards straight pipes (loud ;D)
As for everything else, the first engine is getting polished and cleaned up. It's kinda in peices right now, but I'm waiting on a set of piston rings from Yamaha, they said 2 - 4 weeks!!!! Bike came with a new rear tire, nothing fancy or brand name. Dunno if I'll run it or not. Gotta check into how much a nice set will set me back. I hear Zdeno here in Kitchener is good for tire prices. They're pretty small, so can't cost too much. Gonna lower the headlight and put in an Acewell computer instead of the big instruments that are on there. I think it'll be nice and clean. So, if anyone has a set of clip-ons they want to get rid of, lemme know. I don't remember what the tube size on the 400's are, but I'll check that tomorrow.
Here's some pics of todays work starting with stock to an idea of what I want. The third pic is with a set of bars that the guy gave me cuz he didnt want them. They're ugly as shit, and dont fit. Oh, also bent, but you get the idea of what i'm going for. Hey, there's a happy XS family living in my garage!!
Well, I did it again. Found another bike.... well, same bike, 79 XS400 in blue. Came with a black tank in good condition, and the original tank in blue. HUGE freakin dent in the right side. Looks like the handlebars went THROUGH the side of the tank at one time. Someone patched it up with a welder and put 2 inches of bondo over it. Bars were heated up and bent back, can see the discolouration. Other than that, bike is in decent shape. Only 7300 on the clock, great compression on the kicker. Mine for $350, $40 gas in my buddy's truck, and a couple hours heading to Oakville and back.
Progress so far
She's all tore down already. Already have the ol' wheels spinning in my head about what colours and what to put on it. British Racing Green with Creamy White accents (sorry, flat black is too boring for me
). Should look really sharp...... at least it does in my minds eye. Gonna keep the cast wheels too. Clean up all the casting marks and smooth them out, paint them body and accent colour. Black = Green, Aluminum = White. Gonna lower the front end and put clip-ons above the top tree so they will still clear the stock tank just fine. Gotta do something with the back part of the frame, but I guess I need a seat first. Thinking of making my own outta FG.Exhaust
I'm kinda undecided on the exhaust still. Was originally thinking about doing something like ProTeal's 450 with it up the side, but I checked it out today and I don't think there will be enough room for two hot pipes there. So, the next idea was straight under the frame and engine. Well, this won't work with the front end lowered, I'll be hitting them pipes on everything. I don't really want to go with stock location, but I'm running out of options. Any suggestions? I'm leaning towards straight pipes (loud ;D)
As for everything else, the first engine is getting polished and cleaned up. It's kinda in peices right now, but I'm waiting on a set of piston rings from Yamaha, they said 2 - 4 weeks!!!!
Bike came with a new rear tire, nothing fancy or brand name. Dunno if I'll run it or not. Gotta check into how much a nice set will set me back. I hear Zdeno here in Kitchener is good for tire prices. They're pretty small, so can't cost too much. Gonna lower the headlight and put in an Acewell computer instead of the big instruments that are on there. I think it'll be nice and clean. So, if anyone has a set of clip-ons they want to get rid of, lemme know. I don't remember what the tube size on the 400's are, but I'll check that tomorrow.Here's some pics of todays work starting with stock to an idea of what I want. The third pic is with a set of bars that the guy gave me cuz he didnt want them. They're ugly as shit, and dont fit. Oh, also bent, but you get the idea of what i'm going for. Hey, there's a happy XS family living in my garage!!
Re: 79 XS400
Did a little looking around for 35mm clip-ons. MikesXS has some for $60, but they're only 8 inches long. I found these on ebay http://cgi.ebay.ca/CLIP-ONS-35MM-TOMMASELLI-DUCATI-GUZZI-TRIUMPH-BSA-RACE_W0QQitemZ160147207763QQihZ006QQcategoryZ35610QQssPageNameZWDVWQQrdZ1QQcmdZViewItem
Price is alright, they look pretty decent. 11 inches would be better than the 8 from Mike's. I really like the look of, and the adjustability of the real Tommaselli adjustables, but haven't been able to find some that are 35mm. Does anyone have experience with those ones from ebay? Any suggestions would be great.
Rudy
Did a little looking around for 35mm clip-ons. MikesXS has some for $60, but they're only 8 inches long. I found these on ebay http://cgi.ebay.ca/CLIP-ONS-35MM-TOMMASELLI-DUCATI-GUZZI-TRIUMPH-BSA-RACE_W0QQitemZ160147207763QQihZ006QQcategoryZ35610QQssPageNameZWDVWQQrdZ1QQcmdZViewItem
Price is alright, they look pretty decent. 11 inches would be better than the 8 from Mike's. I really like the look of, and the adjustability of the real Tommaselli adjustables, but haven't been able to find some that are 35mm. Does anyone have experience with those ones from ebay? Any suggestions would be great.
Rudy
Re: 79 XS400
Well, decided last night after talking to a buddy that I'll be making my own TT (under engine) exhaust out of stainless and polish the $H!T out of it. He can get mandrel bends for me, and his brother Tig welds. Should be a bit of an adventure, but I'm sure it'll turn out alright. I'll just have to make sure it's long enough to make enough back pressure. Thinking about flaring out slightly right around where the rearsets will be. May put a small short muffler on each one, depends what I can find.
Well, decided last night after talking to a buddy that I'll be making my own TT (under engine) exhaust out of stainless and polish the $H!T out of it. He can get mandrel bends for me, and his brother Tig welds. Should be a bit of an adventure, but I'm sure it'll turn out alright. I'll just have to make sure it's long enough to make enough back pressure. Thinking about flaring out slightly right around where the rearsets will be. May put a small short muffler on each one, depends what I can find.
Re: 79 XS400
Well, got the engine back together and torqued down. Just finishing up polishing a few pieces and I'll see if I can get it to run. Took apart the forks last night. Everywhere I've looked they sell the 35mm ID x 48mm OD fork seals for these bikes. Well, a slight problem, these forks are 33mm ID x 46mm OD. What gives? How am I gonna find a set of clip ons for 33mm forks? ??? Other than that, all is going well. I measured up for exhaust and I think it's gonna look sweet. Hopefully rearsets will be well on their way this week. No update pics yet, but will come soon.
Have a great long weekend!
Well, got the engine back together and torqued down. Just finishing up polishing a few pieces and I'll see if I can get it to run. Took apart the forks last night. Everywhere I've looked they sell the 35mm ID x 48mm OD fork seals for these bikes. Well, a slight problem, these forks are 33mm ID x 46mm OD. What gives? How am I gonna find a set of clip ons for 33mm forks? ??? Other than that, all is going well. I measured up for exhaust and I think it's gonna look sweet. Hopefully rearsets will be well on their way this week. No update pics yet, but will come soon.
Have a great long weekend!
Re: 79 XS400
Well, spent the better part of the day working on polishing. Bought a cheapie drill press, works wonders compared to the air die grinder (though I still used it for the little tricky bits). Fork tubes look amazing now. Here's a pic of what they looked like before and after. About 1 - 2 hours of work to polish it to that quality of finish. Got the valve cover all polished too, but batteries died in the camera before I could get a pic.
Bought a big piece of 3/8 aluminum plate today for building the rearsets. Almost $90 for the whole thing. Figured I'd save myself the shearing charge and just buy the whole piece. If anybody needs some, I'm sure this will be enough to do my sets and another, maybe two more. I need pegs and bushings yet.
Well, spent the better part of the day working on polishing. Bought a cheapie drill press, works wonders compared to the air die grinder (though I still used it for the little tricky bits). Fork tubes look amazing now. Here's a pic of what they looked like before and after. About 1 - 2 hours of work to polish it to that quality of finish. Got the valve cover all polished too, but batteries died in the camera before I could get a pic.
Bought a big piece of 3/8 aluminum plate today for building the rearsets. Almost $90 for the whole thing. Figured I'd save myself the shearing charge and just buy the whole piece. If anybody needs some, I'm sure this will be enough to do my sets and another, maybe two more. I need pegs and bushings yet.
Re: 79 XS400
Hey guys, thanks for the compliments. It wasnt too hard to get that finish, but here's how I do it.
Start out with 600 - 800 grit sandpaper to take off the worst of the corrosion. Don't sand right through to the metal or you might get scratches that you'll have to buff out later. Use a fairly stiff drum type (cylindrical in shape) buffing wheel about 2 inches in diameter on the highest rpm setting (somewhere around 3000rpm). This will give you a good amount of area to polish with and you can get into the tighter areas fairly easily. Use the black emery (coarsest) compound to get all of the old clearcoat and oxidization off. Try to always work in the same direction as this will keep the "grain" in the same direction and it will just look better when you're done. When you're done that, take a rag and wipe it all down and get any dirt and stuff off. You'll notice the grain scratches now from the emery compound. To get rid of those, take another wheel with white diamond (mid range coarse) and go over the whole thing again. It won't take nearly as long. I used a softer wheel, about 4 - 5 inches around. This will give a more uniform surface, but still not like chrome. To finish off and get that mirror finish I use an 8 inch wheel on the lowest speed setting (I think around 700-800rpm) and use Mother's Liquid Aluminum Polish. Just keep going over it until all the compound is gone and you're left with a really nice piece that you could brush your teeth in.
All of these things are available at normal store. I got the polishing kit from Princess Auto for $30 or something. Came with 3 compounds and a bunch of bobs and buffs. I bought an additional 8 inch wheel. Mother's polish is available at Canadian Tire or any auto store for somewhere around $15. It works really really well with not too much work. From start to finish it only took about 2 hours per fork with phone calls and coffee breaks and people dropping by.
Hey guys, thanks for the compliments. It wasnt too hard to get that finish, but here's how I do it.
Start out with 600 - 800 grit sandpaper to take off the worst of the corrosion. Don't sand right through to the metal or you might get scratches that you'll have to buff out later. Use a fairly stiff drum type (cylindrical in shape) buffing wheel about 2 inches in diameter on the highest rpm setting (somewhere around 3000rpm). This will give you a good amount of area to polish with and you can get into the tighter areas fairly easily. Use the black emery (coarsest) compound to get all of the old clearcoat and oxidization off. Try to always work in the same direction as this will keep the "grain" in the same direction and it will just look better when you're done. When you're done that, take a rag and wipe it all down and get any dirt and stuff off. You'll notice the grain scratches now from the emery compound. To get rid of those, take another wheel with white diamond (mid range coarse) and go over the whole thing again. It won't take nearly as long. I used a softer wheel, about 4 - 5 inches around. This will give a more uniform surface, but still not like chrome. To finish off and get that mirror finish I use an 8 inch wheel on the lowest speed setting (I think around 700-800rpm) and use Mother's Liquid Aluminum Polish. Just keep going over it until all the compound is gone and you're left with a really nice piece that you could brush your teeth in.
All of these things are available at normal store. I got the polishing kit from Princess Auto for $30 or something. Came with 3 compounds and a bunch of bobs and buffs. I bought an additional 8 inch wheel. Mother's polish is available at Canadian Tire or any auto store for somewhere around $15. It works really really well with not too much work. From start to finish it only took about 2 hours per fork with phone calls and coffee breaks and people dropping by.
Re: 79 XS400
I spent a similar amount of time on my front forks. I ended up starting out much lower though, around 150grit because I had some serious pitting and rush. I went all the way up to 800grit with Mirka abralon pads. In the end I just used a foam buff ball with wheel polish. Looks similar but not as lusterous. If I ever figure out what kind of front end I'm going to have on this thing I'll invest the rest of the time...
Here is a great link on Polishing.. I've refered to it many times.
http://www.caswellplating.com/buffs/buffman.htm
I spent a similar amount of time on my front forks. I ended up starting out much lower though, around 150grit because I had some serious pitting and rush. I went all the way up to 800grit with Mirka abralon pads. In the end I just used a foam buff ball with wheel polish. Looks similar but not as lusterous. If I ever figure out what kind of front end I'm going to have on this thing I'll invest the rest of the time...
Here is a great link on Polishing.. I've refered to it many times.
http://www.caswellplating.com/buffs/buffman.htm
Re: 79 XS400
Tore the bottom end apart tonight. First chance I've had to get back to the man-cave in a while. To make a long story short, I lost a little bolt that holds the cam sprocket on the camshaft. Couldn't find it anywhere. The moral of the story, don't put bolts in silly places like inside the crank case. I know it's a pretty safe place, as not too many people will go in there, but it's not so good if it ends up in your constant mesh jungle of gears. Now I'm just waiting on my gasket set from N.L. so I can get this baby back together.
It really wasn't that hard to pull apart and figure out. I was expecting more. Check out the pics.
Tore the bottom end apart tonight. First chance I've had to get back to the man-cave in a while. To make a long story short, I lost a little bolt that holds the cam sprocket on the camshaft. Couldn't find it anywhere. The moral of the story, don't put bolts in silly places like inside the crank case. I know it's a pretty safe place, as not too many people will go in there, but it's not so good if it ends up in your constant mesh jungle of gears. Now I'm just waiting on my gasket set from N.L. so I can get this baby back together.
It really wasn't that hard to pull apart and figure out. I was expecting more. Check out the pics.
Re: 79 XS400
Polishing tips
1) Easy Off oven cleaner will eat through that crappy plastic clear waaaay easier than trying to buff/sand it off.
2) Most castings have a "parting line" or seam that shows. If I'm going to the trouble of polishing the thing I take a fine metal file, followed by sandpaper and remove this line - It's all in the details.
3) Mothers mag and aluminum polish as a final step REALLY brings out the lustre
Polishing tips
1) Easy Off oven cleaner will eat through that crappy plastic clear waaaay easier than trying to buff/sand it off.
2) Most castings have a "parting line" or seam that shows. If I'm going to the trouble of polishing the thing I take a fine metal file, followed by sandpaper and remove this line - It's all in the details.
3) Mothers mag and aluminum polish as a final step REALLY brings out the lustre
Well, with the Canadian dollar doing what it did, I've just ordered a pile of parts. Everything I need except the clip ons, lights, seat and Acewell computer. Should be coming along rather nicely once they all get here. Gotta wait til next month before I can order anything else. Budget, you know.
Got all the parts from Z1 and Mike's. Put the carbs and filters on, and fit the crankcase vent filter. Pretty F-ing sweet looking filters!! The XS on them is what made me pay $16/filter instead of getting some other cheapies from ebay. I know, they're a little big for a 400, but they look HOT! Just gotta degrease a little tomorrow and I'll get her switched for the spare engine in the frame ready for mock up of the exhaust, which I still need to source bends and straights for. I don't know of any shops around here that do mandrel bent exhausts. If anyone knows of a place, let me know.
Got the new kickstart mounted on there too. Had to drill and dremel a hole like a keyway in the starter shaft and the clamp block to put a piece of rod in. The splines on the kicker were all wrecked. This kicker is in much nicer shape than the original and is longer by an inch and sticks further out to clear my rearsets. Should work pretty well when its all done.
Rudy
Got the new kickstart mounted on there too. Had to drill and dremel a hole like a keyway in the starter shaft and the clamp block to put a piece of rod in. The splines on the kicker were all wrecked. This kicker is in much nicer shape than the original and is longer by an inch and sticks further out to clear my rearsets. Should work pretty well when its all done.
Rudy
Fear My Twin
Chicks hate my bike.
Looks really good!
I cant wait to see the end result? Plan on re-jetting I hope?
I cant wait to see the end result? Plan on re-jetting I hope?
I cant wait to see the end result either man! I'm gonna have to rejet, no other choice with open pipes and pods. Jets should be easy to find for these carbs though.
I swapped the engines yesterday. Looks pretty sweet and fits nice and tight in the frame. I have to clean up all the wiring yet. Probably will just create my own wiring with new harnesses and everything. Then I can route it how I want it. The engine I took out had the crankcase full of gas. I went to drain the oil and it was REALLY thin and clear..... and smelled like gas. I guess the float valves leaked as well as the vacuum petcock whenever this thing was parked. So, I guess I'll be tearing this engine apart too. The clutch plates will need to be cleaned for sure.
I swapped the engines yesterday. Looks pretty sweet and fits nice and tight in the frame. I have to clean up all the wiring yet. Probably will just create my own wiring with new harnesses and everything. Then I can route it how I want it. The engine I took out had the crankcase full of gas. I went to drain the oil and it was REALLY thin and clear..... and smelled like gas. I guess the float valves leaked as well as the vacuum petcock whenever this thing was parked. So, I guess I'll be tearing this engine apart too. The clutch plates will need to be cleaned for sure.
Got my clip-ons the other day. Went for a pair of 34mm ones and just tightened them down a little more. Worked out fine, and they're in a pretty comfy position even though they're quite low. Got everything lined up as far as where the controls and headlight are gonna go. Still have to polish the top tree, switch housings and MC and clutch perch. Got the plates cut and polished for the rearsets. Ordered the mandrel bends and straight piping today from Columbia River Mandrel Bending online (http://store.racing-solutions.org/). Didn't really want to order it just yet, but the stuff was on sale!!! Shipping cost me more than the parts, but, oh well, such is life. That should show up sometime next week by UPS. Hope they don't rape me for brokerage, I've heard some horror stories about UPS. So, I guess that leaves the seat and lights before teardown and painting. This is going quicker than I expected. I'll post some pics up when I find some time to get out there. Maybe saturday.
I'll post some pics up when I find some time to get out there. Maybe saturday.Well, pics of the bars on. Nice and low, yet still comfortable with my 6' 5" height. May build the seat up a little higher when I do it. Pretty sure I'm leaning towards glassing one myself this winter. Just ordered signals and tail light off ebay tonight. little cateye signals front and back and a snake eye tail with a license mount. I hope it fits alright, but I guess that would be the advantage of making my own seat. So, that leaves the shopping list at: seat, Acewell guage, and header wrap. Oh, and proably a number of jets.
Been a while since I've had time to work on the project, but should be able to get a few hours in this week. For a while I've had the mandrel bends for the exhaust, signals and brake lights. Haven't had any time to work on them. Rearset pegs and spacers are on their way from the CNC machinist. Should look amazing. Just won header wrap on ebay. 1/16"x2"x50 foot roll with 5 stainless zipties for $15USD. Not a bad price.
I decided I'm gonna make my own seat out of FG. I'll get some styrofoam and shape it right, then make a reverse mold out of plaster and sand it real nice and smooth. Lay the FG in there and away I go. Make it nice and strong with some sheet aluminum laid in the seat and seat back. Then to the wiring and paint. Should be fun. The problem is finding the time.
I decided I'm gonna make my own seat out of FG. I'll get some styrofoam and shape it right, then make a reverse mold out of plaster and sand it real nice and smooth. Lay the FG in there and away I go. Make it nice and strong with some sheet aluminum laid in the seat and seat back. Then to the wiring and paint. Should be fun. The problem is finding the time.
