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78 XS400 Mach1 Cafe Build

Discussion in 'The Garage' started by Spitfire_X24, Oct 30, 2020.

  1. AmbientMoto

    AmbientMoto XS400 Enthusiast

    Looks great! What is your paint process?
     
    Spitfire_X24 likes this.
  2. Fix any dents and scratches up to 400 grit, clean with a wax and grease remover, then prime using a high buildup primer, sand up to 1500 grit, clean using a wax and grease remover, spray on the flat black, I used Duplicolour, then once dry, scuffed using a gray scuff pad. Then I taped off the stripes using 3M 1/4 inch clean edge tape, it's almost like a pinstripe tape, and then I sprayed the blue. Once that was semi dry, i removed the tape and let it dry the rest of the way. Then I used Spraymax Matte Clearcoat 3680065 and while I was at first not happy with how matte it looked, over the course of 24 hours as it cured it came out quite nice.
    This clearcoat is supposed to be very resistant to discoloration due to fuel spills and such.
    The key is patience, and I had some places where a bit more patience would have improved the final outcome, but lesson learnt.
     
  3. AmbientMoto

    AmbientMoto XS400 Enthusiast

    Awesome. I've used Duplicolor in the past with great results but your tank looks better than anything I've done for sure.
     
  4. Thank you very much.
    I found a site (motorcyclehabit) that has some good info, found him on Instagram some time ago and he's got a lot of good helpful info there.
     
  5. Hi guys,
    Not much progress here as of late, with the weather dropping below -30 and staying there for a few weeks, I don't want to weld, grind and paint with the garage doors closed, makes the house "smell funny". LOL, happy wife, happy life. Anyways, it looks like it is going to warm up a bit through out the rest of the week, so i'll take the time to get the rest of the frame modifications done and the bits and pieces painted so I can begin reassembly.
     
  6. A little progress update....
    58.jpg
     
  7. Hi all, been away a while, very busy summer and very little progress on the bike, just getting going on the rewire, and ran into an issue with how to wire the field coil of the AC generator. All of the wiring schematics for bikes with the points style ignition with no TCI show the green wire running to the regulator like on all models, but the other black wire coming off the field coil goes to ground. On this bike, it switches from black to brown at the connector and goes to keyed power not ground.
    I’m building my own harness using Drewpy’s steps and I don’t want to mess this up. I’m going to wire it as it is, with the black wire going to keyed power, but every pre-TCI setup I see has it going to ground. Just seems odd is all, there is no schematic in the Haynes manual that matches my bike completely. It’s like a mix of the 1979 US XS400F model, which it is, and the newer G models.
    Has anyone else run into this?
     
  8. A bit of a progress update on the wiring.
    I removed what I don’t need, eliminated the front key, the headlight relay, and the signal canceling unit and wiring. I built an electronics pan, reseated the front brake master cylinder and bled the brakes and lastly began installing the wiring, or at least mocking it up so I know where to tape the harness together.
    A few pictures of the process. 10F1F806-5EB8-4723-81B8-79CD883F4D2A.jpeg 15E6E001-CCB5-4DDC-A0A1-B09D11804358.jpeg 67084087-7866-43FF-A208-0245B7B53131.jpeg B2E114BA-7074-4527-8761-3AF400BD5A7B.jpeg 677441A3-4BA8-466D-940B-7DE84D73EEF4.jpeg
     
  9. Some progress on the wiring…
    Tested all the circuits and signal lights, headlight, bright/dim, starter works, neutral, and oil pressure lights work, as does the brake lights, just had to adjust the rear switch. I’m stoked! Next is fuel and a test fire to see if she’ll start!
    Wish me luck.
    4B060761-B77A-4E36-B27D-9786E7278907.jpeg
     
  10. Buddha

    Buddha XS400 Addict Top Contributor

    Nice and clean wiring. Where are you locating the battery?
     
  11. Thank you.

    In the back on its side beside the start solenoid.
     
    deeve likes this.
  12. Quick update, I got her running tonight for the first time since October 17th 2020. Almost a year to the day. Connected a fuel bottle to the line and filled the bowls with fuel. Pulled the choke out and about four or five spins later it fired. Lots of top end noise, so I shut it down and let it cool off. I adjusted the valve lash and fired it back up. It will start quite easily fully choked but will rev quite high so I have to cycle back and forth between full choke and half choke until it warms up. It was loud and late so I shut it down for the night. Looking forward to working on it tomorrow evening.
     
    deeve likes this.
  13. deeve

    deeve XS400 Member

    19
    1
    3
    Oregon
    New to the forum and XS400's. Just got two last night-one titled barn find and one parts bike. Reading your build has got me fired up to dive into mine. Great thread!
     
    Spitfire_X24 likes this.
  14. Thank you. There are a lot of awesome builds on here. Check out the two bobbers being built by Buddha, works of art.
     
  15. deeve

    deeve XS400 Member

    19
    1
    3
    Oregon
    Oh I have checked out Buddha's work already. Very talented people on here. I think I would like to move toward a scrambler build for mine. First thing that has to go are those buckhorn bars and seat. I am not sure I have the talent to build a seat like you have. Be nice to find a ready made "regular" bench seat from the era that fits.
     
  16. Buddha

    Buddha XS400 Addict Top Contributor

    Now you've peaked my interest:umm: What type of battery are you using?
     
  17. Looking to install a gel cell or a lithium battery due to their smaller size. The great part is you can mount them any orientation you want without having to worry about spillage.
     

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