81 partial restore, mild race build

[betteron2wheels]

Managed to get enough slack in the chain to get the cam out. freed the pistons with atf/acetone, a wooden hammer handle and large rubber mallet and got the cylinders off. Still haven't had a chance to get the old plug out. I'm hoping I can clean the cylinders enough to hone them and reuse without boring.

 

[xschris]

I would replace the rings ( there is a guy on ebay that sells the standard size) lap the valves and have new seals put inand of course you are going to replace all the gaskets If you have a 30+ year old engine apart you should do it right.

 

[betteron2wheels]

XSChris, that's the plan as long as everything checks out on this engine. do you have a link for the ring-seller?

 

[xschris]

http://www.ebay.com/itm/Yamaha-XS40...&fits=Model:XS400&hash=item540a2d773a&vxp=mtr Here ya go.

 

[betteron2wheels]

Thanks Chris, I need to check that it's still standard size.

 

[betteron2wheels]

I finally pulled the XS out and started work on it again. I got the stuck plug out using a spring loaded punch; the jugs were within spec after a light hone but one of the pistons needed to be replaced because the rings wouldn’t come out. Reassembled the top end over the weekend and get her to run, realized the carb boots are in horrible shape so I ordered a new set I hope will arrive this week.

 

[betteron2wheels]

The Carb boots arrived and are installed, started working on front brake. Going to try to re-use the master cylinder; started disassembly using wooden shims to pry the reservoir off, worked like a charm. Got shims started under lip in 3 places (pic 1), removed 1 and used hammer to lightly tap 2 (pic 2, sorry it’s blurry) remaining shims and wedged it off. Next step is some cleaning.

 

[betteron2wheels]

Wow, almost been a year since my last update.
I pulled the XS out with the resolution to get it working and street worthy. I have pretty much decided to replace any old master cylinders with new Brembos that can be had for about $120.

By the time spend the time and $$ to rebuild the old ones with new rubber and plastic it, it's still the old MC that's probably not the best size anyway.

I have a bunch of new parts here or on the way and hop to have it ready in a week or 2. Probably just in time for the weather to start turning to crap.
.

 

[Wolfe_11B]

Good resource for sizing brake components- http://www.vintagebrake.com/mastercylinder.htm

 

[betteron2wheels]

Looks like it's time for a yearly check-in, this bike has taken on a new theme. I picked up a set of cheap hangers from a swap meet last summer and installed a set of short shocks leftover from a lowered Vulcan. Add some bags I had laying around and, instant bobber/bagger. Still working on a seat and a few details but it's coming along.

 

[betteron2wheels]

 

[betteron2wheels]