1978 XS400-2E Intro and Build

bcware · Apr 7, 2011

As you can see in this photo, which is not mine, the tab is not touching the "tower"/"perch" or whatever, but it should be. This limits the movement of the float and allows it to pivot properly on the pin. In the resting position as shown in the photo it should just be touching the perch. When the tab is not touching the perch there is a lot of slop and play in the float and it is very difficult to adjust the height using the tang in the middle that rests on the needle.

I am guessing this happens a lot when you bend the center tang by pushing against the float while it is resting on a flat surface; you end up squashing this tab. It bends back easily with pliers.

bcware · May 6, 2011

I thought I would post a few interesting things I have come across while rebuilding my bike.

All balls steering stem bearings:

I managed to install these without any special tools. I literally used the stock steering stem races, triple tree, and a block of wood. The following instructions might be a little hard to follow, however!

I used a block of wood to pound in the new top race. For the new bottom race I stacked two of the stock races together as shown in the photo and taped them in place with masking tape; simply whack away with a rubber mallet. To drive the new lower taper bearing on to the lower triple tree I used the stock lower race from the lower triple tree; remove the stock lower race from the lower triple tree, slide on the new taper bearing, flip over the stock lower race and slide it over the new taper bearing, take the upper triple tree and insert a fork leg "loop" over the stock lower race and new taper bearing; whack the whole assembly with a rubber mallet.

Balancing wheels and tires:

I really didn't want to order bearings and I could not find anything local. I gambled on a patio roller replacement set and it just so happens that steel rods from the hardware store fit in these bearings perfectly. See the photos for how I set this up. A local dealer gave me wheel weights for free.

staycryptic · Sep 27, 2011

Whatcha been up to, dude?

bcware · Sep 27, 2011

I bought a 1996 Suzuki GSX-R shortly after "finishing" the XS400. When the gixxer is down for maintenance I ride the XS. I still have not had any problems with it since I drilled new threads for the spark plug even after about a thousand miles. Oh, and I also taught my mom how to ride on the XS

She took the safety course after and has a Ninja 250 now.

As for plans I intent to pull the XS apart again this winter to clean it up further, paint the frame, and install a proper, reasonably comfortable seat. Other than that the XS has been rock solid and wheelies pretty good

Attached are some photos of the gixxer; before and after I painted it. The previous owner dropped it a few times, but getting rear-ended by a truck at a red light is what pushed me to tackle the job.

sageone · Sep 27, 2011

how is the career coming? are you in med school?

bcware · Sep 27, 2011

Right now I am finishing up all of my secondary applications. After I am done with these I wait and see if any of the schools want to interview me. If the interview(s) go well I am either accepted, wait-listed, or rejected. It is rare to be rejected outright after an interview as people are thoroughly screened before this stage.

So, this is where I am at right now. The entire process is grueling and very drawn out. I really can't wait to be done with the last of these applications! It doesn't help that they are very expensive too.

sageone · Oct 5, 2011

Wow, I can only imagine. Hang in there, it will pay off.

bcware · Oct 5, 2011

I started the winter rebuild. Tearing the bike down to the frame took one day.

cmoore352010 · Oct 7, 2011

How many builds will this make for you?

bcware · Oct 11, 2011

This is the second "build" of the same motorcycle. I'm quite impatient, so the first time around I threw everything together quickly just to pass inspection and ride. This time around I am going much more slowly, but there is still going to be a lot of room for improvement in the future.

Here are more progress shots:

bcware · Oct 14, 2011

Crappy phone pic update:

bcware · Oct 15, 2011

Daily update:

I spent hours trying to get a frozen bolt out, drilled it, broke an extractor in it, drilled the extractor out, broke a bigger extractor in it, currently drilling that out...

leedutcher · Oct 15, 2011

tank looks really good!

drewpy · Oct 15, 2011

Driller Killer

bcware · Oct 18, 2011

She's a roller.

I tore down the top end yesterday. Closer inspection revealed a leaking head gasket and a lean right side. Gasket and oil seal kits are on the way.

drewpy · Oct 19, 2011

rock 'n roller

bcware · Oct 19, 2011

I finally got the cylinder block off; it was stuck by the gasket. A propane torch did the trick. The lower gasket was completely soaked with oil. I don't think that is normal!

Does anyone know if typical gasket kits come with new o-rings/seals for the oil inlets in the head? Should I reuse them? I bought an athena gasket set and an oil seal kit so far, but they won't be here for a bit.

xschris · Oct 19, 2011

It should come with those o-rings. I would not reuse any gasket or o-ring, bad idea. Oh, I sent your cap out today should get it in a few days.

drewpy · Oct 19, 2011

the Athena kit has everything except the main oil seals.

it has the red O rings which go under the barrels, O rings for the cam caps, o rings for the rocker retainers, valve seals and all the gaskets

bcware · Oct 20, 2011

I intend to clean this up a bit more, but I roughed up a brake light and license plate mount by bending 90-degree shelf brackets by hand with a hammer, vice grips, and bench vice.

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