Petew XS400 brat scrambler build

[Petew]

So what new parts exactly did you buy for them? You just cleaned up the valves and lapped them only?

This is my first engine build in a bike......I know they are a little simpler than a car but hell its been 30 years since I rebuilt an engine and that was a VW

I did a cylinder hone to polish them a touch, cleaned the carbon from the combustion chambers and piston, did a valve lap. I resealed the entire engine except I did not split the cases or remove the rocker assembly as no wear showed. I had new rings but didn't use them as the others look great and measured to spec. Basically, I bought an overhaul gasket set for $35.00 and the rings I bought for 26 dollars will go into the other motor when it gets done,
I also went through the carbs.. I am not so sure about "easier" than cars...most cars have a lot more room to work with. I worked in auto repair field for 20+ years and felt quite capable there....this was a learning experience. The next one will be easier.

 

[spectra]

Been a while we need updates

 

[Petew]

Been a while we need updates

Nothing to update Spectra,still sitting waiting to get put in. Busy music schedule the past 3 weeks. I walk by it daily and wish i had more time ( and an extra set of muscles) to get it done. I did wire up the new spade fuse box and make a new front brake cable. Hopefully Tuesday or Wednesday next week it will fire up. I also ordered a set of Uni air filters while I've been waiting and started to overhaul the second set of carbs....time, money and muscles, things I wish I had more of!

 

[spectra]

Nothing to update Spectra,still sitting waiting to get put in. Busy music schedule the past 3 weeks. I walk by it daily and wish i had more time ( and an extra set of muscles) to get it done. I did wire up the new spade fuse box and make a new front brake cable. Hopefully Tuesday or Wednesday next week it will fire up. I also ordered a set of Uni air filters while I've been waiting and started to overhaul the second set of carbs....time, money and muscles, things I wish I had more of!

Summers coming to an end.........you have to get at least one ride in

 

[Petew]

That's the goal! If not I fear my imagination will start me thinkin'....I have my second one waiting for over the winter!

 

[spectra]

That's the goal! If not I fear my imagination will start me thinkin'....I have my second one waiting for over the winter!

Yeah and then your third will show up

 

[Petew]

...and my brother just bought a welder...I'm going to try and learn how to use it. You know what kind of fun THAT can bring about!!! Bobber style next...

 

[Petew]

....and my new filters showed up today. ON virtually everybodies recommendation I ditched the Emgo cones for a set Uni's. Motor goes in tomorrow and maybe running by Thursday! I am stoked. While I have been waiting I can't stop shopping for upgrades. I am looking at adding directionals after all...we'll see. I am still fighting myself about tires . Mine are the 16 rear 18 front spoked wheels and I can't decide between a street tread or a trials type tire....damn, this gets hard sometimes!

 

[Petew]

Thanks to my younger, and stronger, brother I have gotten the motor back into the bike. Tomorrows the day to finish installation and wiring. With luck there will be a running XS400 in the driveway. I have also decided that directional signals might be a good thing to have so I ordered 4 low profile blinkers that shouldn't alter the look too much. Once I have it running I can go about hiding what I want hidden and upgrading what needs that. Tires next...

 

[xschris]

It's a good idea to have good visible lights on a bike. If people can't see what your doing your more likely to get hit.

 

[tmatter]

I have also decided that directional signals might be a good thing to have so I ordered 4 low profile blinkers that shouldn't alter the look too much. Once I have it running I can go about hiding what I want hidden and upgrading what needs that. Tires next...

Can't wait to see what your solution is. ️

 

[Petew]

I decided today that the headlight ears didn't fit the look I wanted, I ordered a new set that will compliment the blinkers nicely, gives me a chance to neaten up the nest of wires in the headlight housing. I also painted the lower fork tubes black and added my pinstriping to the tank. My phone is on the fritz so I don't have any pics...yet! Overall I am pleased, just concerned at this point about the shifter. I am conflicted as to whether to fill the bike with oil and give it a go after starting it or pulling the cover off and checking clutch/shift pawl...we'll see.

 

[Jeff0133]

Fill it,give it a try.

 

[Petew]

Ready to start, I thought....something electrical is not connected correctly. Time to trace and test!

 

[Petew]

The cause of the no crank was a bad ignition switch, Some place along the line I had lost the key that went with the bike. No problem, I had a perfectly good switch sitting on my bench from another '80 G. I swapped them and proceeded on with my wiring etc. On a chance I had a new key made for the original cylinder after I had exhausted all the other possibilities. Along with the no crank my rear light would go out when I used the brakes...I was clueless A wing and a prayer they say...I switched out the cylinders and I get all functions and it will crank over. I will spend some time charging the battery and reassemble what I have taken apart and hopefully she will fire off...so close now I can taste it!

 

[spectra]

Good to hear you got it figured out......hopefully it fires up for you.

 

[Petew]

Good to hear you got it figured out......hopefully it fires up for you.

It was soooo frustrating. I went over every connection, traced on the schematic, tested wiring . It cranked like a son of a bitch before teardown! Finally I looked at the pieces I replaced. New starter solenoid,blinker relay and ignition switch, it was the switch/cylinder that was bad.
....feel like a dumbass for losing the key in the first place. How is yours coming along?

 

[spectra]

Well the 400 is pretty much done. All I really need to do is check the adjustment studs or whatever they are called......to see if there pitted. I just don't like the noise......although I know these motors are noisy.

Am just starting the big one......

Well did you get it running ?

 

[Petew]

Well the 400 is pretty much done. All I really need to do is check the adjustment studs or whatever they are called......to see if there pitted. I just don't like the noise......although I know these motors are noisy.

Am just starting the big one......

Well did you get it running ?

Battery needs charging and it's raining here...I'll wait and see.

 

[Petew]

Got new headlight brackets installed along with low profile LED blinkers for the front and rear. Picking up a new battery today, discovered that the one I have been using drops off so much under load it is a wonder that it cranks things over at all. I can get 1 cycle through before it goes dead. I am hoping that this is the final step, outside of tuning and synch'ing the carbs, and I will be able to get a few days of riding time. I know the bike's battery is missing,

I was trying to show the blinkers and headlight mounting...