1981 XS400 Scramblerized Build, eventually...

Did you lace up 16" or 18" rims?? I'm thinking of using 16" rims for a stockier looking stance. But I'm not sure if the tire will fit in the forks like it's supposed to.
I laced up 18" rims. I wanted to be able to find matching tires, and a 16 and 18 combo did not work for me. There is plenty of space if you want the front and rear to match at 18". 16" may be an issue in front if you are running a fender for clearance.
 
I laced up 18" rims. I wanted to be able to find matching tires, and a 16 and 18 combo did not work for me. There is plenty of space if you want the front and rear to match at 18". 16" may be an issue in front if you are running a fender for clearance.
Thanks Jim I kinda figured that you laced another 18" rim to the rear drum. Seems to me that is about the best way to go for me too.
 
Busy weekend so far. I needed to get the Yamaha at least trial assembled for the upcoming tech day so I could get it out of the garage and taking up space. Basically this is what it will look like when done. The wiring and a few other details are still waiting on more time by me, but I think it is pretty OK.

To get the engine in I laid the engine on its side and lowered the frame with wheels over it. I taped the frame to minimize damage while my lovely assistant helped me lower it over the engine.
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One bolted in, I put it on the lift, then replaced most of the original motor mount bolts with stainless steel.
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Then I started bolting on parts, all basically trial fitting. Most will come back off for final detail and fitting. Exhaust first:
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I need to do something with the heat shields. I don't like them much and the fit is crap.

Next came the carbs and foot pegs, shifter lever and rear brake parts. And the instruments, headlights and rear light assembly.
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Parked on the lift out of the way so I can clean up the garage for the tech day.


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Jim :cool:

PS I accidentally crushed my oil filter canister and bolt under my lift. Anyone have a spare they could sell me?
 
Oops, time gets away from me sometimes.

Opened all the wiring up and started sorting wires and connections according to the wire diagram. Some of the wires were different colors, so I had to trace all of them to make sure they were correct. I also wrote down every wire and color and what it went to. Lots of work, but better at my desk in my office than in the hot garage trying to figure it all out.

Old wiring was a mess, and confusing. Missing lots of parts.
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Wiring diagram from the here..
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New/used harness, likely from a different model as some of the wire colors are not right. But it should work. Removed the nasty and sticky electrical tape, then dug in marking all the connectors and loose wires.
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Hopefully I got it all right. My only question is the generator/rectifier white wires. How do I know which wire goes to which wire, or does it matter?
 
So, 7 hours later, a little cussing, lots of testing, and the wiring is done. Don't mind what looks like scratches all over the frame, it is the loom material leaving greasy like marks everywhere. It comes off. I also discovered that I need side covers. The first realization was when I laid the pipes back in and realized the wiring is just an inch from the pipes. Then I saw how busy the wiring looked, so side covers it is!

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Everything was tested and works, though I do not know for sure the charging system works. That will have to wait on the full reassembly.

Overall I am OK with it, not thrilled with the wiring organization, but I wanted full functionality. If I had left off the turn signals it would have been a LOT simpler.
 
Great job! Not much that can be done to help organize it more than it is with the stock components and connectors.

I think yellow side covers will look really good. Helps the yellow carry through the whole bike.
 
I'm sure you've been told numerous times but I'm going to also tell you that you've done some Beautiful work here!!! One thing I've thought for your side covers is Aluminum Diamond plate. With your theme as a Crossover type adventure bike diamond plate would be a nice addition and you could use some for a skid plate. For me there's 1 thing that looks out of place here. Some reason your seat to me needs to be a bit larger & to fill the tank to seat gap I'd put some sort of storage container.
 
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