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78 xs 400 E rebuild and modify

Discussion in 'The Garage' started by Tyler Shiells, Mar 30, 2017.

  1. The front of the tray is wide open and the back has a opening at the top. I think it will stay nice and chilly in there once moving.
  2. xschris

    xschris a lifestyle not a trend Top Contributor

    Remember that the heat from the motor will be pulled through there also.
  3. Just prepping for paint today.

    Questing regarding the rear shocks...

    Are these caps decorative?

    And would it be safe to reassemble them without?
    I kind of like the look without them.
  4. xschris

    xschris a lifestyle not a trend Top Contributor

    They do help keep things aligned. I ran them without for a while but went back using them. Don't leave out the rubber bump stop. It also helps keep the slide from dirt/rust build up. Make sure to put it back together tight with the lock nut. They can go loose.
    Tyler Shiells likes this.
  5. Paint really does bring an old bike back to life.

    20200202_150532.jpg 20200203_181213.jpg 20200203_181220.jpg 20200204_102325.jpg 20200204_105349.jpg

    Based on previous experience with VHT Rollbar paint, I used again with this bike. Satin black was the choice.

    Still a few more parts need painting yet but the parts needed to get this rollin again are done.

    I also have a shipment of parts in the mail, hoping they arrive in time for the weekend.
  6. This wknd I made a table stand, from random lumber I already had, so I can reassemble the bike easier.

    Also I got some parts in the mail.
    New handlebars
    Shinko 712s and new tubes
    Front wheel bearing and seals
    Fork seals

    And now it's starting to look like a bike again!

    20200210_182255.jpg 20200210_185019.jpg
  7. xschris

    xschris a lifestyle not a trend Top Contributor

    Do you still have the side cover tabs you cut off?
  8. 20200211_114300.jpg

    I belive that's them. But I didnt exactly cut em off with the thought of anyone wanting them.
  9. xschris

    xschris a lifestyle not a trend Top Contributor

    Those are it. They look a bit messed up. I see your in Canada. Shipping will be a fair amount more than if I just try to find some in the states. Thanks anyway.
  10. I could maybe send em through letter mail? I'd just wrap them in something as to not puncture the paper. Wouldn't cost more then a stamp, just no tracking. I can ask the post office if you like?
  11. xschris

    xschris a lifestyle not a trend Top Contributor

    Wont work in an envelope. Need to be flat like paper for that. I do a lot of shipping it would need to be in a small box or a larger padded envelope.
  12. motoTrooper

    motoTrooper XS400 Addict

    What kind of clearance do you have between that rear tire and the underseat electrics box? In the photo it looks to be an inch more or less? I know that the axle is at the front of the swingarm slot but still you may have interference issues with the bike assembled and rider weight compressing the suspension.
  13. Good eye. Thanks for bringing it to my attention. There wasnt enough clearance with the shock fully compressed.
  14. Thanks to mototroopers keen eye I had to adjust my electronics tray.

    With the new tires I was about 2 inches shy on clearance. So I came up with this solution.
    20200215_184229.jpg 20200215_184250.jpg 20200215_184525.jpg 20200215_184638.jpg
    Took a little bit of puzzling over and a few measurements and double measurements but it turned out decent. I think it looks even better. The fuse box with sit on the angled piece. Kinda cool and functional.

    Now the tire clears with the shock fully compressed to the rubber stop.

    Thanks again mototrooper for pointing that out.
    Last edited: Feb 15, 2020 at 9:26 PM
  15. motoTrooper

    motoTrooper XS400 Addict

    Happy to help, man. You've got a good build goin'.
  16. More parts came in yesterday.
    Sprockets and chain.
    The paint on the rear caliper was a complete disaster from obvious brake fluid spills over the years. So I stripped it bare and decided I like it without paint.
    Will end up stripping the front caliper as well.

    Also brain storming some ideas for a way to mount a seat pan. And decided I'm going to put a bridge back over the rear, for extra support if a passenger is riding along.
    I measure and there is a 1/4 in clearance under it while the shock is fully compressed. I'll be making the seat from fiberglass so it will be able to fit exactly and mount to the bridge support.
    I by no means want a thin seat. I plan to ride this bike. My seat will probably sit about 4 inches thick with pan, foam and upholstery. The foam over the the bridge will have to be slighty thinner but that's fine as a passenger won't be a common occurrence. Plus I want the seat height even with the taillight.

    I just need to figure out a way to make a back sealing plate for the taillight that can can be mounting at the same time.

    I'm thinking of using led bulbs in the taillight with a custom way of mounting them internally, so I can have the back plate flat instead of bulged like the original...hmmm
    motoTrooper likes this.

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