Brat ‘82

IanW

IanW
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I have been working on this build for a number of years now (with help from this forum). I figured I should start posting a build log to share and to keep myself progressing.

The donor was an '82 XS400 with 26K kms and very few modifications. I stripped the bike down to the frame and have removed most of the paint and the back section of the seat support. I managed to get an 18" rear wire wheel to match the 18" front.

Here is a mock-up of where this is currently headed:

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Carbs are in process of a rebuild:

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Motor is completely apart and I have just enough parts now to start re-assembly.

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Connecting rods back on today... think I may have over-tightened one of the new bolts. Done now.
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I just cleaned the stator up a bit. The motor had about 20K miles on it so was not in bad condition when I cracked it open. I probably could have left it alone and driven it for another 20K ... but that would not have been any fun.
 
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After all the trouble of joining the case, the gear selector mechanism was acting sticky and I had real trouble getting all six gears to shift reliably. Broke the case back down again and rolled the selector rods on a sheet of glass to make sure they were flat. All good. Noticed the wear pattern was backwards on the front slector rod, so I put it back together with the rod reversed. Now all is good. I get six gears with little effort. I guess the wear pattern being reversed made the selectors stick a bit causing rough shifts. Lesson learned.
 
Top end together and starting to work on the aluminum covers. Also changed the name of his thread from bobber to brat because that is where things are going for now...

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After you put the motor back in the bike remove the tappet covers and fill the cam baths with oil. I would also kick over the motor a bunch of times with the ignition off to get the oil pumped up where it need to be.
 
Working on the forks now. Springs are perfectly equal length of 498mm, which might be worn down from the stock 502mm, but the spring cross section is also slightly thicker than another pair I have of 500mm.

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