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Cafe build

Discussion in 'The Garage' started by tonupNW, Apr 18, 2011.

  1. tonupNW

    tonupNW xs newbie

    Well I picked up picked up a 1980 xs400 special the other day for 60 bucks, couldnt pass it up. Gonna do it up cafe style with modern touches here and there. Im sure I'' be turning to quite a few of you for help along the way as this is my first yamaha. The bike is rough as its been sitting outside in the NW, not much rust, mostly just moss and full of leaves pine, needles and what not. I tore into it today, got it down to a roller and tore into the motor. Motor is gonna need some work, looks like someone was in there at one time and didnt know really what they were doing. So its gonna get cleaned up, full reseal, Fix the shift shaft (missing e-clip letting the shaft move in and off the shift forks) and mabye some magic on the head while im in there. Here are some pics of when I picked it up and when I tore into it today. Also those are not the bars im gonna run, that is just a piece of pipe to move it around. I couldnt stand looking at those beach combers that were on there
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  2. new kid on the brat

    new kid on the brat new kid on the brat

    nice!! way to jump in there and get s#*t done!!! looks like you know what you're doing!
     
  3. hammerlo

    hammerlo Iron Horse Riders

    60 bucks!!! damn i wish i could buy motorcycle for 10 gallons of gasoline, anyway, love Cafe Racers, i`ll follow your work :thumbsup:
     
  4. cafedan

    cafedan XS400 Addict

    175
    0
    16
    great start man! ill be following as well.
     
  5. tonupNW

    tonupNW xs newbie

    Thanks guys. Im gonna strip it down the rest of the way today or tomorrow and this weekend have the frame and swinger blasted and have the cases walnut shelled to shine them up a little.
     
  6. XSrocker

    XSrocker XS400 Enthusiast

    Hey! I am going to be following this as well. I am looking into putting some modern touches on mine as well.
     
  7. drewpy

    drewpy Excess twin Top Contributor

    this is gonna be good, keep us up to date man :thumbsup:
     
  8. tonupNW

    tonupNW xs newbie

    Any ideas or tips on splitting the case? Ive been beating on them with a rubber mallet and it wont budge. I may try to heat it up to see if that will soften up whatever the hell the used to glue it together.
     
  9. drewpy

    drewpy Excess twin Top Contributor

    you have missed screws!
     
  10. tonupNW

    tonupNW xs newbie

    Found the problem. There was one more bolt that had grime and crud all packed around it and missed it originally. All good now.
     
  11. tonupNW

    tonupNW xs newbie

    Well worked on the bike a little today. Because I'm anal retentive and a perfectionist, I started grinding down all the casting marks on the cases, rocker cover, pretty much anything that had casting marks, bumps, eyesores, got smoothed out. Bad part is I started polishing. Now I'm gonna have to polish everything lol. Here is a few pics of the rocker cover in rough form. Still need to do about another hour or 2 of smoothing it the way I want and then the polishing begins. I think in the end its all gonna pay off.
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  12. bcware

    bcware Well-read Top Contributor

    Good luck holding back; look what happened to Drewpy's tracker; it's turning into a show bike! I want to do some cleaning myself, but at the same time there is plenty of time in the winter to polish and restore to high standards.
     
  13. tonupNW

    tonupNW xs newbie

    Well I broke down... I ordered a buffer/polisher and lots of compound. Time to get dirty
     
  14. tonupNW

    tonupNW xs newbie

    Here is a sneak peak of what im gonna use for an exhaust. Let me know what you all think
    [​IMG]
     
  15. bcware

    bcware Well-read Top Contributor

    It would look out of place with the baby seat, but should look great once you've converted to cafe :) You really can't go wrong with a small muffler. Are you going to run 2 to 1 headers?
     
  16. tonupNW

    tonupNW xs newbie

    Im gonna build a set of stainless equal length 2-1 into the shorty muffler.
     
  17. Lovin the exhaust man! It will surely look killer on a cafe style bike! I feel your pain on the polishing....I've got about 4 months worth of mine, just here and there. It SUCKS!!!!
     
  18. dO-bOy

    dO-bOy Woohooo!

    please tell me you're keeping the seat...
     
  19. tonupNW

    tonupNW xs newbie

    Haha I may keep it, but there is no way in hell its going on the bike again. It rubs the hell out of the tank because its so big.
     
  20. tonupNW

    tonupNW xs newbie

    Well Im debating on tires right now. I really like the Bridgestone Battlax's, but want to know how well a 130/90/16 will fit. If it does, then this will seal the deal on my tires
     

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