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1978 XS 400 Cafe Racer from Germany

Discussion in 'The Garage' started by ThomasLoco, Oct 2, 2016.

  1. ThomasLoco

    ThomasLoco XS400 Member

    Hi guys:),
    my name is Thomas, I'm 23 years old and IT-ecomics-student, located in germany right next to the alps:cool:.
    I ride since I'm 18, when I started on a Husqvarna Supermoto.
    My bike for daily adventures is a 2014 Triumph Street Triple R with lots of mods.

    I would like to show you my current project, a 1978 XS 2a2, which I bought last year and started rebuilding over the winter.
    I'm not quite done yet, lots of details and technical stuff.
    Mainly the dropping voltage is the problem, which I can't solve at the moment.
    The rest is stuff like carbs cleaning, ignition etc. (shouldn't be an issue)

    So here is a little list of the things that are changed/new so far(I'm sure I forgot the half of it:whistle:):

    -Fehling handlebars
    -Fork-rebuilt with progressive springs
    -Telefix forkstabilizer
    -brake-rebuilt with Melvin Stahlflex-brake lines
    -Daytona Velona speedometer
    -full K&N Airintake
    -Spokewheels from a RD250 + Conti ClassicAttacks
    -1981 swingarm for drumbrake
    -new bates-style headlight
    -electric charge regulator
    -LiPo battery
    -Motogadget turnsignals
    -Brembo PS12 breakpump
    -Koni or YSS rearshocks (got both)
    -new clutch + lever
    -shortened frame
    -Tarozzi footpegs
    -conic short exhausts
    -aluminium front fender
    -new camshaft for full power
    -new DID chain & sprockets
    - custom seat & rear
    -sky blue paintjob
    -LSL Clubman grips

    I hope you like her.
    It's my first built and I had to teach me everything by myself during the process:D
    So be gentle with me:confused:

    Best regards from germany


    Attached Files:

    Last edited: Oct 14, 2016
    IanW and Jeff0133 like this.
  2. Jeff0133

    Jeff0133 XS400 Junkie Top Contributor

    Nice and clean.
  3. Lego

    Lego XS400 Addict

    Great build.. proper stuff :) my question is: where did you get that bigger camshaft in europe? I have also restricted version. From US?
  4. ThomasLoco

    ThomasLoco XS400 Member

    Yeah, just look on ebay for camshafts. I think they wered used in England to.
    Last edited: Oct 3, 2016
  5. dgoodsy

    dgoodsy XS400 Enthusiast

  6. Looks Great! Very well done! I was very interested in the Tarozzi rearsets. I've looked at them but was under the impression they didn't make them for the XS400s. Am I wrong or did you adapt them from another model? They look like they've addressed all the problems I couldn't get around, like a cutout for the rear brake shaft!
  7. ThomasLoco

    ThomasLoco XS400 Member

    Thanks guys!:)

    The baseplate is cut from 8mm alumium. The footpegs + levers are from Tarozzi.
    If you ned a template, here you go;)

  8. Thanks, I made some plates last winter but wasn't satisfied with them. Maybe I'll try again with this template this winter. Until I'm satisfied with the plates there is no need to worry about pegs and levers.
  9. drewpy

    drewpy Excess twin Top Contributor

    welcome, nice looking bike Old mose.
  10. IanW

    IanW IanW

    Great build. I like the straight lines.
  11. ThomasLoco

    ThomasLoco XS400 Member

    Thanks :)
    Currently I am waiting for shitty weather to get started in the garage again.
  12. Hi and Welcome Thomas, you have done a really good job, on your 400, and you say you are self taught too? I myself have too many bad habits, after working in the motorcycle industry (Norton-Villiers-Triumph, R&D dept, for five years)
    Considering that you are self taught, your work is extraordinary, and looks well planned in advance?
    Well done Thomas

  13. LuckyEight

    LuckyEight Head-scratcher

    Beautiful...especially the tail section:thumbsup:
  14. ThomasLoco

    ThomasLoco XS400 Member


    Yup, I started out with zero prior knowledge, bought decent tools und just went for it. I didn't do any planning beforehand, just looked at a lot of pictures on instagram and all sorts of Cafe Racer websites to get some inspiration. It's more of a process, sitting in front of it, picturing all varieties and deciding for one.
    a little help from forums and the good old workshop manual did the trick so far:laugh2:

  15. All the more Respent for you then Thomas, As I said I have a background in the motorcycle industry. But, my first effort at a conseptual build, didn't even come close to your build, both in Aestetic's or the technical aspects.

  16. ThomasLoco

    ThomasLoco XS400 Member

    Thank you, I really appreciate it:)

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