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I had my mind in a knot over a simmilar issue. Turned out the right point assembly wire was toughing and shorting to the motor! If you havn't checked where the points wires are attached to the points, I would =)

How is the rear fender assembly? cracked/bent?

any pics of front fender? I'll take it if it's good!

Looks pretty good. What about the rear? No cracks/bends?

sounds good

Looking for front/rear fenders with no cracks or bends. Rust is OK as I will paint them if they are super bad, otherwise chrome is ok. Something that fits a 1978 xs400? Thanks

my chain guard had about an inch worth of goo in it. I think its mostly a gathering place for chain lube and dirt.

Been a while; School is almost out for the summer Finals week!! arg! Motor is done, valves set, ready for me to put it back in the frame once I'm done with exams! I had the covers powder coated and painted. The same goes for the sprocket cover and other engine bits. I'll post more...

I am digging the rear cowl and licence plate mount!

are you talking about the black plastic things that are press fit on the very top?

It looks like that was the problem. I needed a good whack to the head to get my brain going on this problem, thanks guys =D Now if i could just get the darn lines on the cam sprocket to stay nice and parallel with the top of the case once the tensioner is in.. haha

Ohh ok, I made sure that the the pip marker was at 12-oclock as the manual states, but I don't remember setting either side at TDC, I swear I read that thing at least 3 times before I installed it. I'm sure that's the problem then, I will adjust the cam chain sprocket accordingly. Thanks

So I've got my motor pretty much complete after a full tear down and I've run in to a snag setting the valve clearances. If I loosen the valve clearance adjusters the motor turns over freely no problem. If I try to set the valves to tolerance by tightening them (LT) first, then (RT). The...

Zinc plating! Parts are turning out okay; my technique needs some improvement, but its still pretty cool =D Quick ride today after work/before working on the XS

Yep! soda blasting is a great way to get that carbon off =D

Yeah man shoot me a PM when you're around! Both of the stands I have I got from harbor freight. Cheap, and you get what you pay for, but they work.

More stuff done today; finished the valve cover Installed it; but now I have a problem =\ I can't get the motor to rotate a full 360, I can get about 180 degrees out of it or more before it abruptly stops. This is about as far as I can get it to turn. What the heck! Quick edit; Just...

Laced the wheels up with some chromed spokes from ebay. Had the rims powder coated; they were rusty and in shabby condition. The powder coating place I found ground and sanded off all the imperfections. They turned out really well, I don't have a pic of the before, but the spokes were a rusty...

Motor is almost finished! Just need to finish up the valve cover and then wait to get the other covers back from powder coating.

Bought a flex hone; about 28$ on ebay, Keep it nice and oiled and run it back and fourth in each cylinder fairly quickly at a medium RPM, breaks the varnish and gives the metal a nice cross-hatch pattern without increasing the bore diameter; just don't do it for too long.=D