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If the bearings and crank journals look ok its worth using Plastigauge (https://plastigauge.co.uk/) to measure the clearances, you might not need new bearings at all. Con-rod bearing clearance is 0.021-0.045mm. Main bearing clearance is 0.020-0.044mm.

I've got an XS400 SOHC build ongoing, like you I want to loose the original separate regulator and rectifier. I've chosen an XS750 combined unit, mostly because the wiring colours are the same and I could get a brand new one cheap on eBay. XS400 reg/rect wiring: XS750 reg/rect wiring...

I've had my supermoto'd XR600 for 10+ years, it doesnt even have a speedo and it's passed it MOT every year (at 2 different testing stations I might add). Not that it means its 100% legal, but neither MOT man has ever been bothered by it, maybe I just got lucky. Either way my XS400 will be...

Progress has been slow recently, change in role at work means I actually go into the office rather than working from home so less opportunity to get into the garage. Bought a new AGM battery for the bike so knocked up a racy style battery box to hold it, started off with a sheet of 1mm thick...

Its been a while since I updated the build thread, but progress has been happening, its just slow and fiddly. I bought 3 rear mudguards before I found one with the right profile, once I was happy with the shape I welded in a spare seat hoop as a frame brace / mudguard support: Then welded on...

Personally, I am not an expert on plating. My advice would be to contact a company who IS. I used Dynasurf: http://dynasurf.co.uk/motorcycle-forks/ but I have also heard very good reports on Philpots: http://www.pittedforks.co.uk/ They will centreless grind the stanchions back and apply new...

I had the stanchions from my TDM900 rechromed a couple of years ago. I had to phone around to get the best price but basically they come back as good as brand new, probably better than buying pattern parts. I think I paid around £100, but the cheapest I found after a quick google is £145 now...

Just to keep this updated, I will not be beaten! So far I've bought the following: Crankcases, brand new 250 crank (lighter than the 400!), xj1300 con rods, gpz900 pistons, head with cam and rockers, new cam guide, new cam chain, gasket set, clutch pushrod (the old one was snapped in half!?)...

By the way, if anybody here is looking to go down the big-bore route, I had to buy a set of four XJR1300 conrods, so I have two going spare.

Thanks for the video link Drewpy, I'm more inclined to save a few quid now and make my own copper gasket, anybody on here ever done it? My only concern is how much torque is required on the head nuts, I'm thinking as the whole cylinder head surface needs to seal now, rather than mostly relying...

No worries Drewpy, had a feeling you might be in the market for one! Are you running 75mm barrels tho? Phoned a company in the UK today, they guessed at less than £100 each but said it would be cheaper if I did the CAD work, that’s in fibre with metal fibre rings.

It depends which route I take, if I go with the GS500 (74mm) pistons then I will need to machine both the liner OD and the barrels and case to take the larger liners, but this has been done before by others, I just hope I can convince the machine shop at work to sneak it in... Regarding the...

I was hoping you would reply Drewpy, you were in a lot of the threads on this and other forums. What are your plans regarding head gaskets?

Hey guys, I know this topic has been covered before, but no-one mentioned what they did about the head gasket? I found a company which makes custom head gaskets to order, I imagine probably expensive. I also considered using annealed copper sheet and getting it water jetted or lasered, but...

No worries guys, let’s look on the bright side, now I’ve got justification to swap out the crank for a 250/360 one, and the rods can go in the bin and get some FJ1200s ready for some bigger pistons . Bit bummed about the crank cases and the head/cam tho.

I started at the top (obviously) and straight away it was obvious this engine is in a bad way. Camshaft is scored and burnt on the center journal and one lobe (the others are not great) so thats scrap: Cam follower/rocker arm is also scored and generally f**ked: Centre "bearing" journal...

Soooo, having already invested a fair amount of time in the frame of my cafe racer project, I thought I should probably look into the engine, especially as when I bought the bike the engine was knocking more than a very knocky thing. I warn you guys, this thread contains images which some...

That is some serious gusseting! Puts my welding work to shame too, well done! As a bike to ride I imagine its going to be fairly awful, but as a piece of art its going to look great. Definitely following this build closely.

Why would anyone put an XS400 engine in a quad? Don’t get me wrong, I love my little XS for what it is, but I can think of a hundred better engines for a quad. Got any pictures?

Not much chance to work on the bike around Christmas, so I had to make up for it by spending money on eBay... Bought an air filter (I’ll create a separate post with that, I’ve had a novel idea instead of individual pod filters...) And a pair of these bad boys: Stock silencers from a Triumph...