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Loving this build, stunning looking bike! Can't wait to see it finished...

I'm a coded welder/fabricator and more than capable of welding it but having spent 7 months building the bike only to discover the casings cracked I tried to JB Weld it from the outside just so I didn't have to strip the whole engine!! JB Weld obviously didn't work and can't really be used...

I've checked on the 250 and it's definitely not a casting mark as both have different cracks but in the same place. it seems to be the return stop for the kick start throw. As it returns it hits the same spot inside the case and this is where it's cracked internally and externally. As the engine...

Hi guys, I wondered if anyone else has had this problem? I have a small crack in the case at the rear engine mount. Its in a recess that if you take the side casing off, looks to be where the kickstarted mechanism spring fits against. I have included a couple of pictures. I have cleaned it up...

Thanks. Heres a few more...

Thought I'd add mine to the modified XS400's. Originally a 1981 4G5 that wasn't running, which I bought for £200. 300 man hours later, this is the result. Oh and it has 23" Honda XL250s rims front and back with 3 inch wide tyres! Makes for fun riding! :D

If it doesn't work I'll look at a gravity fed gun. Cheers Chris :thumbsup:

Today, I mostly played with bags of baking soda and air lines to try and perfect a soda blaster to clean my carbs. First few attempts weren't promising, but I think I might have cracked it. Will post pics if it works:thumbsup:

I have Pod filters and open headers with no baffles and had loads of issues getting mine to run properly. Mines a 1981 4G5 model and that had a 125 main jet, 42.5 pilot and washer on 4th slot on the needle. I ended up changing to a 45 pilot which was a vast improvement and then up to a 140 main...

Today I cut the threaded end of an old bicycle crank and welded it onto the original kickstart arm. I added a white rubber Union 9/16 pedal and hey presto an old school look which is much easier to start now!!:)

Didn't like the kickstart and fancied an old school pedal look, so I cut the threaded end of an old bicycle crank and welded it onto the original kickstart arm. I added a white rubber Union 9/16 pedal and hey presto an old school look which is much easier to start now!!:D

For the fuel tank I made a paper template, then when I was happy with the shape used that to cut the 1.2mm steel shapes out, then welded it all together. The compound curves were hard to get right! That took a few evenings work!!!

Thanks. I made it out of some 1/4" car brake pipe!!!!

A couple more Pictures...

Thanks a lot.

The filter pods are RAMAIR units about £20. Bought mine from RAMAIR direct.

Thanks! No nickel plating. I machined two brass tube/covers. There's lots of brass bits on the bike.

Hi from sunny Cornwall, UK been here a while for info and technical help, but thought I'd finally introduce myself and my finished XS400 board tracker. Its taken 7 months of weekends to finish and all modifications, frame/tank fabrication, paint, wheel building (23" front and back) controls...