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Somebody put a lot of heart and soul into this build, one of those bikes that inspire.
http://www.bikermetric.com/2011/09/reader-rides-drews-yamaha-xs400-street.html
:thumbsup:Excellent Work, Drewpy
Do you plan to keep the seat as is, or do something different? That would have a bearing on the total flow of the bike design and maybe a decision on what type shape and size tank you want to make.
Sometimes the problem goes beyond the explainable and you need to call a professional in.
Seriously though, as Drewpy said, we're giving as many ideas that we can think of, based on what you're telling us. They may or may not help, but they are worth checking out. Your TCI could be...
Do you have a multimeter or just a cheap continuity tester? Use that to check kill switch and ignition switch. Check for continuity across the fuse box. Do you have access to a wiring diagram? Here's a link from the forum:
When you tried starting, shouldn't need to hold starter button for more...
Did you charge the battery after you topped it (low amp charge, 2 or less)? Do you have a multimeter to check charging system on bike, should be around 13v at idle, to 14 or so at higher RPM.
I don't know how proper this was. One time I was replacing the seals on a Honda. that probably hadn't been replaced since it was new, about 30 years. I couldn't do any of the usual to get them out. Getting frustrated, after a couple days working on it I got extreme. I stuffed wet rags into the...
Have you looked at the color of your plugs? Sure both cylinders are firing? Did an ohms test on you coil? Checked the resistance of spark plug caps? Compression? Valve shims? Timing chain tension adjusted? Enrichment or choke working properly, on when you want, off when not? Lots of possibilities.
Welcome to the forum. There are several different models of XS small twins on this form, most ranging from the 360 to 400 Single Overhead Cams to the '82 and up XS/XJ 400 Double Overhead Cams (I think there are also a couple 250's). Go to the tech section, you'll be able to find more info on...
From the tech section under suspension: http://www.xs400.com/forum/showthread.php?t=4553
Here's a link to lowering XS650 forks. http://www.xs650.com/forum/showthread.php?t=5537
The forks are different, but the principle is the same.
Also, the online manual you can download, covers forks...
I checked the parts PDF at Yamaha ( http://www.starmotorcycles.com/partviewer/default.aspx?ls=star ),
for the carbs http://www.starmotorcycles.com/partviewer/default.aspx?ls=star#/Yamaha/XS400J_-_1982/CARBURETOR/XS400J_%281982_MOTORCYCLE%29/CARBURETOR_%28XS400J_-_1982%29 and for the DOHC there...
I think you'll need the rubber plugs, I know my carbs, from an '81 have them. Copied this from the carb guide, page 9 of the PDF file
Mike's XS has them.
http://www.mikesxs.net/products-39.html#products
Z1enterprises, sold in a set of 4...