Sandrew's XS400 - v2.0

Sandrew

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Re: Sandrew's XS400 - Facelift in progress !

Rather than just fixing what was broken I decided to go even further with tweaking.
So it's safe to say vol 2.0 is happening.

I'm gonna do c/p posts from xs400.net as I did a few years earlier.
Here goes:

...

It was what it was...
On to the future now.

Since the bike is in my home town and I get to go home once or twice a month and half the times I don't even make it to the garages, which means, making all the planning and drawings while I'm away and use the few days to make them count.

So in the past month and a half I've spent a few evenings on it. First off was ripping it back to molecules and throwing away what's damaged. Then sorting out which parts to order and what to repair.

I knew one thing, when I'm gonna rebuilt it, I'm not just restoring it, rather facelifting and detailing the things I didn't care to last time around.

Main ideas:

1) new paintjob (more eye-catching and maybe more race-looky)
2) more agressive stance
3) new frame color
4) Swapping out everything that still made it feel old and worn out.

Starting with the small things.

Big scratches on the right engine cover. Easiest way was sanding them out and polish. Now matching the left side. Came out nice me thinks.

Then:


Meanwhile:


Now:


Then new forks came along. Only item on the local market and the price was exceptional. Minor marks here and there, in overall good condition. Really like these silver tubes instead of gold ones, will go better with my color scheme also gold would be leaving rest of the bike in shadow.


But they will receive a cosmetic update.
Now that I've ridden it without front fender for a while without the rain bothering me that much, not further thought was given:


Cone:


And disappeared:


Next up was lower yoke. I hate the molding lines.. These casting molds cost like million euros each and yet they can't make the end product more refined.:) Time to pick up the file.

Beff:


Aff:



Big plans for top yoke also, more on that later.

Last but not least, with the modern front end my vision of the stance change a bit. Nothing drastic yet makes a huge different compared to the old picture (Best way to look at it: subframe rails and bottom of the tank were previously parallel to the ground). To achieve this stance I need to move upper shock mounts 6 cm lower along the frame rails.



So much for now. Hopefully some progress in a months time.

...

It's been well over a month now, but I didn't have anything update worthy until this weekend.
In the meantime I've gathered some parts like new bars switches, foot pegs and stem bearings.


And finally got around to do the frame modifications. Firstly, off went the old steering stopper and two unnecessary brackets on neck area which I for some reason forgot about the last time. New stopper welded on.


Then some additional bolts welded on for electrics to avoid using double sided tape from now on. Also scratches that came from the crash are gone.


I don't know if I mentioned this but I wanted lo lift the rear end about 6 cm, so to make it happen I modified old upper shock mounts and left only the threaded plates in place. They will now act as my turn signal couriers. Neat solution I think.
Before:


And after shaving:


New mounts. They look rough atm, but once sandblasted and a little tweaked, should look as good as new.

Hopefully get it blasted next week, then under some powder and reassemble may begin.

Upper yoke.
The top yoke didn't look so good with the Aprilia branding and those ugly bar mounts, although it had potential in it so instead of machining out completely new one (which would have been less time consuming), I decided to cut it up a little (as usual for me).
I don't have a picture of it before (Maybe LuckyEight can help out with the matter).
Firstly it went in the CNC table face up to remove about 1 mm from the top to get rid of the Aprilia branding.

The we flipped it and milled the underside nice and even:


As I only had a short window with the machine, I figured I finished the sides off with grinder and file. Took about 4 hrs but I think we have a product.


Also started with the cap.


Updates should be coming a bit more often now.

Sander
 

Sandrew

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Re: Sandrew's XS400 - Facelift in progress !

Had a rather progressive weekend, got my frame blasted earlier this week and also frame and some other bits powder coated.



Wait what, frame not in black. I know, shocker, right?

But one simply can't go without some matte black, so there is that:


New bars and Nissin radial brake master with ASV lever:



And it's a roller again!


The silver/black theme is turning out to be even more awesome than I had envisioned:




Liking the cap a lot.


And how I left it tonight. Update probably in a fortnight.



Sander
 

MILLENNIUM FALCON

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Re: Sandrew's XS400 - Facelift in progress !

Looking good man! I'm glad to see ya back at it. Any details about the crash? I read back through and didn't see much. If you don't want to talk about it...i understand.
 

Sandrew

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Re: Sandrew's XS400 - Facelift in progress !

Happy new year !

December was a crazy one, exams in school and busy times at work. Altough I didn't let my bike-time suffer from it. :)

The second end seems close and I still haven't closed on body colors yet.. Was wondering about Yamaha's red/white but don't know anymore.

I promised it sooner but anyway here's what's been going on:

Fork dust covers arrived, so go them assembled and front wheel back on. As you can see, it sits a little to the left (6 mm to be precise) with the stock rotor side flange.


So the extra 6 mm had to be machined down.


Now that the wheel was centered I could take some further measurements for speedo drive replacement.


Some more machined aluminium bits for kickstarter and tacho removal as well ass a stainless bushing for one of the forks to convert 15 mm axel to 25 (The other side, 20 mm, was a perefect fit without effort).



Then my headlight arrived:



Kick-starter removal inside


and out


Tacho plug and new tiny horn installed. Decided to put this accessory back on for 2 reasons, firstly I had one unused button on my switch panel and secondly... the crash might have been avoided, but we'll never know.


Wiring on the new switches sorted and mounted. Horn button acts as starter like it did with old switches and the 'hi pass' works as horn now. I like it.


Got the headers coated again, this time with some better paint. Also the bar end turn signal arrived, unfortunately managed to break one already.


Sander
 

Sandrew

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Re: Sandrew's XS400 - Facelift in progress !

Slowly towards the second end..

Front brake fluid reservoir came in, a bit modifying to get it to sit horizontal and as low as possible.


Dash was also waiting for me at home. So lots of thinking and wiring I got it all working nicely. After everything was sealed up I realized when switching to high beam, the low beam didn't die, which means the bulb would last about 30 minutes if even:). As I wired it up so when the ignition is on the low beam is also on. Only solution there was to add a 5 pin automotive relay, that switching to high would kill low. The hardest part was to fit it all in the light basket..



Then made a nice and simple bracket for the dash from 3mm aluminium.


And mounted:




Well, this happens when you suddenly realize you have ground off all the 'unnecessary' brackets on the frame and got to dig into engine mounts. Actually great spot for it, comfortable to switch when sitting on the bike and no way to hit it accidentally.




Sander.
 

Sandrew

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Re: Sandrew's XS400 - Facelift in progress !

Another one so soon you say?

Well I'm in a hurry, I'm off to Germany for some time in March. So i need to get it finished, pictures taken and put it back on the market again before I leave.

Fisrtly little something from water jet:


Last patch of machined goodies. Bronze this time.
Extensions for caliper bracket. One of them houses the speedo sensor as well:



And the set up. Don't mind about the bolts, will be replaced with proper allens and slotted in to make it more flush.




Speedo magnets slotted into rotor bolts:



Sensor in place:



Also finished the gas cap, man it came out nice, therefor you'll not be seeing this small detail in full just yet.:)
All it took was just some stainless hardware, little machining and a rubber washer.





O and my bar ends. Actually don't recommend the product in question very brittle aluminium and weak soldered connections. They look nice, tho.



And last but certainly not the least, the thing I've been meaning to do as long as I can remember. The rear mount for the cowl. I didn't like the rubber trim I ran last year to keep the cowl from vibrating and therefor scratching the frame. I needed somthing more stationary and simple to hold it separated with about 1 mm.
Put an hour into it and we have a product:


Locks down with a butterfly nut like the rest of the seat.

I actually like the look of those acid resistant / stainless countersinks in there.


I'm glad to announce that as of this weekend everything besides paintjob is done! So next time on the front page, haha. :)

Sander
 

honda53rider

77 XS400,73 SL350, 73 RD350
Re: Sandrew's XS400 - Facelift in progress !

The version 2.0 is looking grate! Hope to see the new build up on pipe burn!
 

Sandrew

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Re: Sandrew's XS400 - Facelift in progress, nearly done!

Barambarambaram, not just yet.. :)

Bought new bolts for brake bracket, didn't like that the heads were of a different height, so a little machining and looks like a real deal.





Well the beast is painted! and very nicely done. My idea, friend's sketch and pro's realization. All Yamaha paint codes. Wanted to make it noticeable that it's still a Yamaha after all, just with a little twist to leave a sophisticated modern look.







Don't mind the mirror is as dirty as your gf's panties, we'll get to that later.
Yup you see it correctly, the blocks don't line up. I don't know if it was just a little mix up or what, put I told the painter that the button line difference between tank and tail were 25 mm, for some reason he only marked the difference about 10. What a bombshell..



Rather than having the cowl redone and wait another week + spend my lunch money (like there's anything left..) I got another idea. Raised the tank again a few notches. At first I thought it would ruin the stance, but the reality was that it made the bike look even more killer and aggressive. And what's the most important, the speed blocks line up like they should.



It was an easy fix, tbh. I had previously made the two piece tank mount from bronze. So I just flipped one underneath the tank's bracket and swapped out the rubber mount.

before:


now:


This also solved another thing that was bugging me for some time. I had made the seat pan a bit too long so it ran under the tank about 2 cm, so it had to be compressed in place. Although it didn't mind me that much to have the seat redone.

You can see what i'm talking about on the picture below:


And now the tank sits on the seat without compressing it.


I also could swapped the YSS's back as the shocks are now in geometrically sharper angle, which results harder feel to them. They also go better with the paint scheme and look more modern-ish.

Now the heavy lifting to get it out of the basement..

Sander
 

johnu

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Re: Sandrew's XS400 - Facelift in progress !

Excellent work for sure, awesome build. Just one question; why do you have magnets in all of the rotor bolts?
 

Yamaki

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Re: Sandrew's XS400 - Facelift in progress !

Nice build, you really did take it to another level with vol.2

Glad to see you got back in the fight instead of giving up after yhe crash, very inspiring tbh!
 

Sandrew

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Re: Sandrew's XS400 - Facelift in progress !

johnu said:
Excellent work for sure, awesome build. Just one question; why do you have magnets in all of the rotor bolts?
Well it gives 6 times quicker response, than using just one measure point, simple as that. Also wasn't that hard work, so why not .:)
 

johnu

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Re: Sandrew's XS400 - Facelift in progress !

Sandrew said:
Well it gives 6 times quicker response, than using just on measure point, simple as that. Also wasn't that hard work, so why not .:)
Oh I'm not knocking it, just curious that's all. Does that mean that you divide the tyre circumference by the amount of magnets to set the unit up?
 

Sandrew

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Re: Sandrew's XS400 - Facelift in progress !

Noup, the unit does all the hard math, I just entered the number of magnets (6) and the tire circumference (1924, which is just initial starting point for 100/90-18, will sync it later on with gps. )
 

Sandrew

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Re: Sandrew's XS400 - Facelift in progress !

Time to wrap it up..

http://www.dotheton.com/forum/index.php?topic=57604.new#new
 

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