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77 xs400 second chance

Discussion in 'The Garage' started by cbrfxr67, Apr 2, 2019.

  1. cbrfxr67

    cbrfxr67 XS400 Member

    7
    1
    3
    HOuston
    Friend brought this over to try and get it running and if it ran ok, to make it a somewhat reliable little bike for him to cruise back and forth to work on. Story was that it'd been sitting in a storage for 18 years.
    [​IMG]

    First off, this crappy fuse block,...
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    ordered a generic one
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    wired in
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    got power
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    super cheap forks off ebay that are in great shape!
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    poor bike
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    sad
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    super cheap seat off ebay! the old pan was rusted out so this was a good score
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    swap out forks
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    ,....
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    old ones rusted badly
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    new cheap grips
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    these forks seem a tad longer or maybe they're not as saggy as the old ones
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    fixed this crappy signal
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    picked up some cheap intake boots off ebay - these are cheap for a reason! the vacuum tubes are not tight as you can pull them out with little effort. I ended up screwing a small bolt into each one. Garbage.
    Going to order some better ones before this is over,....
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    slowly coming together
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    fun with carbs
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    ordered some replacement air filters and was waiting for them. too impatient to wait so stuck on some pods i had lying around
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    pod
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    this gave me stress headache. i didnt have the cable and ended up making the end piece after finally finding a cable that would work. next to find was that the fork i had, was for disc brakes and i had to swap the lower to have the correct drum brake stopper. fun fun
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    carbs were giving me a pita so was going to try these. Canned this idea after finding the cause of my high rev problem was the pilot screw needles were broken off in the carb body. After I got them out all was smooth sailing. THAT was a lesson in frustration for me also. (i searched all over the place for high rev syndrome and after being certain i didn't have an intake leak double checked to find the broke needles blocking the passage)
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    That's about where I'm at now. Sorry for lengthy initial post but after I couldn't find a 'solved' thread for my high rev issue I thought I should post concerning the pilot screw needles blocking the passages. I think that's likely an easy thing to do, as in screwing them in too tight and fubar-ing their purpose.

    Still to go is rear drum brake and tire and,....maybe some clean up. I wanted to keep it looking like a survivor instead of shining it up too much.

    Please any opinions, critiques or tips welcome. Thanks for letting me be a part of this great group!
     
    buztabuzt likes this.
  2. hell of a start!
     
    cbrfxr67 likes this.
  3. xschris

    xschris a lifestyle not a trend Top Contributor

    The bike you have there is a 78 2-E model. You can use those fork tubes if they are off a sohc xs400 model. Just keep the drum wheel fork lowers so your wheel fits like it should. https://www.yamahapartshouse.com/ This is a good site for parts/assembly diagrams.
     
    cbrfxr67 likes this.
  4. MajorRichardWeed

    MajorRichardWeed 1982 XS400

    Almost threw up looking at that original fuse box. Looking good so far! Hope your friend is paying you well, looks like a lot of work. Good luck!
     
    cbrfxr67 likes this.
  5. cbrfxr67

    cbrfxr67 XS400 Member

    7
    1
    3
    HOuston
    Lol major! I gave it a half handed chance to work & cut it out of there.



    Got it out of the garage with new back tire. Not even ashamed I cut that petrified tire off! Was cussing a storm.
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    I can't believe how loud it is for a 400. Need to tune it a bit. Couple small things to clean and tighten up and hopefully sending it home. First experience with an xs and makes me want to find another one and fix it. Missed one on cl for $200 a week back.
     
    Last edited: Apr 8, 2019
  6. MajorRichardWeed

    MajorRichardWeed 1982 XS400

    It's crazy how loud they can be! Super fun to work on, if you see another good deal definitely pull the trigger. Worth every penny
     
    cbrfxr67 likes this.
  7. xschris

    xschris a lifestyle not a trend Top Contributor

    The stocks exhaust would have not been as loud as the ones you have on there now.
     
    cbrfxr67 likes this.
  8. cbrfxr67

    cbrfxr67 XS400 Member

    7
    1
    3
    HOuston
    [​IMG]
    just a shot of my cobbled battery box. I hacked a 900rr tray down and riveted on some mounts. Actually came out pretty sturdy and I was able to chunk that old metal, rusty, tetanus ready, box in the scrap pile.

    [​IMG]
    headlight acting janky & opened it up to see what's going on there. Ive never seen a bulb as the whole assembly so that was kind of cool. I want to fit an led somehow. I have some parts in basket cases and might have a donor to use. Really don't want to change the original styling,....
     
  9. MajorRichardWeed

    MajorRichardWeed 1982 XS400

    That's the exact problem I'm having right now. I actually came on here to get the wiring diagrams because I just got a new universal fit led headlight assembly off ebay. If I get it all working I'll take pictures.
     
    cbrfxr67 likes this.
  10. cbrfxr67

    cbrfxr67 XS400 Member

    7
    1
    3
    HOuston
    [​IMG]
    'bulb' with rust dirt inside,... I ordered an led replacement everything but the more I thought about it, the more the led look is not going to be 'right' for a survivor bike. I used drill press and hole saw to cut out the bulb part, then cleaned up with carbide burr. Epoxied in a bulb holder from parts bin, and stuck an amber h4 halogen bulb in it.
    [​IMG]
    Ordered an h4 led to swap out the halogen. I'm not going to say how much time I spent on the wiring. Almost shamed on that one.
    [​IMG]
    Changed oil filter too but it didn't look too bad,...next i need to go for an extended ride to see if any issues pop up.
     

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