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  1. burr

    1981 XS400 Engine Build: A Story of Pictures, Videos, Beers & Tears

    Uh oh, did I do a bad thing? I've been using a Milwaukee M18 Impact driver. Also - any tips on adjusting the throttle? My plan is to to examine where the throttle cable hits the carbs first, then move to the handlebars.
  2. burr

    1981 XS400 Engine Build: A Story of Pictures, Videos, Beers & Tears

    Thanks for ALL YOUR HELP SO FAR. Really felt like i accomplished something today. Recommencing tuning tomorrow, ran out of time tonight. A couple things before I take her for a real ride… The throttle doesn't spring back right now. Any tips how to do that? She's leaking oil out of the left...
  3. burr

    1981 XS400 Engine Build: A Story of Pictures, Videos, Beers & Tears

    Cancel that guys, JUST STARTED HER UP!!!!! She sounds like this: :gun: Idle is crazy fast right now. Needed a push start. Smells terrible (probably because of burning stuff off). Need to fix throttle hand lever, not connected right now… BUT SHE STARTS
  4. burr

    1981 XS400 Engine Build: A Story of Pictures, Videos, Beers & Tears

    So guys, bike should be all ready to start up, so I'm trying it now and… Good News: Got some pretty excellent compression. 145psi right, 143psi–ish left. Happy about that.:cool: I put at most a tablespoon's worth of oil in the cylinders 4 days ago. So not sure if this qualifies as "dry" or...
  5. burr

    1981 XS400 Engine Build: A Story of Pictures, Videos, Beers & Tears

    Hey @BBS360 that worked!!! The clutch is now fixed. Gear changer is still not shifting but that's tomorrows problem....
  6. burr

    1981 XS400 Engine Build: A Story of Pictures, Videos, Beers & Tears

    My plastic covering has kinda shredded as well, between the actual clutch handle and the part that attaches to the handlebar. I'll continue to monitor it
  7. burr

    1981 XS400 Engine Build: A Story of Pictures, Videos, Beers & Tears

    Riiiiiight. Forgot about the black rubber plug thingy. I'll certainly do that adjustment. Here's the suggestion from the official Yamaha Manual
  8. burr

    1981 XS400 Engine Build: A Story of Pictures, Videos, Beers & Tears

    Interesting. It's nice to have a specific test to do, rather than fiddling and adjusting without a real method to it. I will try this today.
  9. burr

    1981 XS400 Engine Build: A Story of Pictures, Videos, Beers & Tears

    Yes, have adjusted the clutch at the lever end. But.... What adjustment at the worm gear are you talking about? From what I examined, there's nothing to adjust. I also didn't see anything in the manual about adjustments to the clutch cable inside the sprocket cover. Seems like the only...
  10. burr

    1981 XS400 Engine Build: A Story of Pictures, Videos, Beers & Tears

    Urgh yeah I was thinking that's a possibility, but thinking it over I find it hard to see how they could even be installed incorrectly.... Considering the case is all sealed up, bearings are in the guides, etc.
  11. burr

    1981 XS400 Engine Build: A Story of Pictures, Videos, Beers & Tears

    Little update. Kickstart seems to work just fine, mechanically speaking. Definitely getting some compression, but didn't have my gauge and will test it tomorrow to be sure. I was getting a 'glug glug glug' kind of globby burping sound at the bottom of the kick… anyone know what that means? Is...
  12. burr

    1981 XS400 Engine Build: A Story of Pictures, Videos, Beers & Tears

    So, let's keep the pics going… Pic #1 details where the shift pawls grab the dowels (or actually, where they are BLOCKED with the plate pawl inside). The arrow shows where the upper shift pawl is resting on top of the plate pawl (blocked by the plate pawl from grabbing dowels). Q#1: Can you...
  13. burr

    1981 XS400 Engine Build: A Story of Pictures, Videos, Beers & Tears

    Little update from yesterday – I dismantled the clutch basket and played around with the gear selector assembly. Turns out I had forgot a thin shim between the pressure plate and the clutch boss (part #168-17428-01-05, or #27 in the catalogue). I also put it all back together with a bit more...
  14. burr

    1981 XS400 Engine Build: A Story of Pictures, Videos, Beers & Tears

    i don't think that was the cause, although I'm a newb. It's more likely that some debris got inside the left carb. otherwise both cylinders would look destroyed.
  15. burr

    1981 XS400 Engine Build: A Story of Pictures, Videos, Beers & Tears

    After more reading, I think that it may be one of two things. 1. It may be that I have installed the shifter assembly in a high gear. Hopefully I can correct this. I'll drain the oil, remove the right cover, remove the clutch basket, and turning the shift cam manually back to neutral position...
  16. burr

    1981 XS400 Engine Build: A Story of Pictures, Videos, Beers & Tears

    Thanks EthanL. But what do you mean "hanging up?" Do you mean when the friction plates are staying stuck to the steel clutch plates? I made sure to apply oil to each surface before installing, so that would be weird i think. If you could explain in more detail though… ________________________...
  17. burr

    81 xs400 shifting issues

    Hey @Face , ever solve that gear change issue? I have a similar problem … when i use the left foot gear shifter, there is no engagement with the gear change shaft. It's like the shift pawls (on the right side) don't want to 'click' into position on the gearchange drum/Shift Cam (the thing with...
  18. burr

    1981 XS400 Engine Build: A Story of Pictures, Videos, Beers & Tears

    I removed the stator cover and tried manually turning the stator bolt - it turned, but with difficulty. There was a little bit of springyness to it, and I could see the drive sprocket and chain moved just a little bit. Not sure what that means but at least the drive train isn't actually stuck
  19. burr

    1981 XS400 Engine Build: A Story of Pictures, Videos, Beers & Tears

    Guys, I'm at a big of a loss here, and getting pretty discouraged about this. Today's issue is the same as last time. I cannot get the kickstart to turn, or the rear wheel to move at all. I can't roll the bike to get the transmission moving, because the rear wheel won't turn. I can't shift into...
  20. burr

    1981 XS400 Engine Build: A Story of Pictures, Videos, Beers & Tears

    The amount of things I don't know is slowly decreasing.... Thanks @NewHavenMike will try that soon.
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