1981 XS400 Scramblerized Build, eventually...

JimVonBaden

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I picked this up from an inmate the other day:

XS400%203_1.jpg


For him it was a bobber project build.

from this:

XS400%201.jpg


To this:

XS400%206.jpg


He started out chopping the rear and relocating the shocks, then adding a seat pan, plus a bunch of work.

XS400%2011.jpg


XS400%2035.jpg


XS400%2030.jpg


XS400%2022.jpg


XS400%2021.jpg


XS400%2015.jpg


XS400%2011_1.jpg


XS400%204_1.jpg


(photos courtesy of his photobucket account, and mine)

My plan is to beef up the suspension, beef up the shock mounts (they are fine for street, but I am big and need them really strong), redo the wheels (but keep the drum brakes) and generally make it look period, but very clean and newish looking. I even hope to fab a set of high pipes for it.

Just a first look:

XS400%2039.jpg


Note the modern 2015 R1200GS seat foam and cover I hope to add. I plan on changing the tank to something smaller.

I want pipes similar to this:

pubadybu.jpg


and paint like this except Yamaha yellow:

XS650-Scrambler-2.jpg


XS650-Scrambler-4.jpg


The overall look will be similar, but a lot less chrome.

I warn, it will not be a fast project, but I will eventually get it done.

By the way, any suggestions for Scrambler type tires to fit

R 90/16 4.5" wide 120/90/16

Fr 350/18 3.75" wide, 80/100/18

Preferably matching.

Jim :cool:
 
Last edited:
At this point.

I ordered a pipe build kit, since I can't really bend my own. I also ordered a new tank, cap, valve, filter, hose, spark plug caps, battery, Speedo/odo/indicator gage. They should be in within a week.

sporty-frisco-mount-chopper-motorcycle-gas-tank--292.jpg


xs-650-builder-exhaust-kit-for-your-chopper-bobber-or-cafe-build--66b.jpg


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My plan is to get it started and see if it is mechanically sound, then fab all the pieces and get them fit up. once I have what I want, I will strip it to nothing but pieces and start the powder coat, paint and polish. Lots of steps in between to post about.

Jim :cool:
 
Looks like a cool project with some interesting history behind it.

Do you have a welding torch? There are some pretty amazing exhaust systems done by hand, hot bending sand packed pipes with a torch. No fixed radius limitations to the bends like bought kits or even mandrel benders.
It's something I want to try some day.
 
Looks like a cool project with some interesting history behind it.

Do you have a welding torch? There are some pretty amazing exhaust systems done by hand, hot bending sand packed pipes with a torch. No fixed radius limitations to the bends like bought kits or even mandrel benders.
It's something I want to try some day.

Thanks. It is a project bike that the PO bought from a military guy, the PO is also military, and has had for 5 years with little progress. If the story is correct, it started about 9 years ago and each owner has made a little progress. I hope to break the trend!

Jim :cool:
 
welcome! always wanted a scrambler... 16'' rear might limit the available dirt/ dualsport tires out there
 
Got in the parts. I am a bit conflicted on the tank, but I think it might work aesthetically.

Build%20Parts%2009-17-15%202.jpg


Build%20Parts%2009-17-15%204.jpg

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Build%20Parts%2009-17-15%206.jpg


Sitting on the bike:
Build%20Parts%2009-17-15%2016.jpg

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I also got in the pipe kit. I think I can make it work.

Build%20Parts%2009-17-15%203.jpg


I'll get started on the weekend, but I am quite excited to get going.

Jim :cool:
 
Had some free time to work on the XS Scrambler today.

First I hooked up a battery and used a little starter fluid and it cranked right up. It ran fine, so I shut it down and proceeded to mod it.

First on the agenda, since I wanted to make sure I could actually do it, was the exhaust.

It started like this:

Build%20Parts%2009-17-15%2016.jpg


I used this kit for custom exhaust:\

Build%20Parts%2009-17-15%203.jpg


Then proceeded to cut and grind to fit the pieces up and make the whole.

Exhaust%20Build%203.jpg

Exhaust%20Build%204.jpg

Exhaust%20Build%205.jpg

Exhaust%20Build%206.jpg

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Exhaust%20Build%2013.jpg

Exhaust%20Build%2015.jpg

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Once positioned and tack welded, I took it apart and welded the rest. Not a great job, but it looks pretty good to me. The flapper wheel is the crappy welder's best friend.

Exhaust%20Build%2033.jpg

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Exhaust%20Build%2035.jpg


Not even close to perfect, but I am happy with it.

In the end, I hope to make it good enough to ceramicote, or at lest high heat paint.

More to come!

Jim :cool:
 
A little more progress today. Took about three hours to remedy a deficiency in the mods done by the last owner. The rear frame where the shocks mounted were basically U-brackets welded to the end of the frame tube. no reinforcing. Since I am a heavyweight and the bike will doubtless get some off pavement use, I needed to add some steel to the shock mounts.

Started like this:
Frame%20Reinforcement%204.jpg

Frame%20Reinforcement%205.jpg


Note that the frame rails just ended, with little keeping them from spreading, and not very strong brackets to hold the shocks.

Made a paper template for each side:

Frame%20Reinforcement%201.jpg

Frame%20Reinforcement%203.jpg


Found some 3/16 mild steel to make a cross brace:

Frame%20Reinforcement%206.jpg

Frame%20Reinforcement%207.jpg

Frame%20Reinforcement%208.jpg


Used similar 3/16 mild steel for the frame braces.

Ready to weld:
Frame%20Reinforcement%209.jpg

Frame%20Reinforcement%2010.jpg

Frame%20Reinforcement%206_1.jpg


Tacked in place:
Frame%20Reinforcement%2011.jpg

Frame%20Reinforcement%2013.jpg

Frame%20Reinforcement%2018.jpg

Frame%20Reinforcement%2022.jpg


I need to touch up my crappy welds, but this should be plenty strong now.

Jim :cool:
 
So long as the welds penetrated, don't be so harsh on yourself :) Using a hobby mig in the garage will never yield a pretty weld like a $2k + machine will. And heck, just look at the stock welds on the frame, I always feel better about mine after looking at those!
 
So long as the welds penetrated, don't be so harsh on yourself :) Using a hobby mig in the garage will never yield a pretty weld like a $2k + machine will. And heck, just look at the stock welds on the frame, I always feel better about mine after looking at those!

I'm confident of penetration. Besides, the flapwheel is your friend!

Thanks,

Jim :cool:
 
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