cracked kickstart journal

volcomskater77

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my journal is cracked off for the kickstart. what can i do about that? would it be worth welding and pressing in a roller bearing or something? or should i just get a new block?
 
I assume that you mean where the kick shaft fits in the case and not the cover. If it was the cover just swapping the bad for a good would be easy.
The hole in the case where the kickshaft fits is a bit more work. Being it's in the upper case you will need to totally tear the engine down to weldup and rebore a hole in the case.
At that point you would need to price the weld and rebore to cost of replaceing the cases. Yes cases, the upper and lower cases are a matched set. They are line bored for the crank and the transmission shafts. Then numbered. If you mis match the cases you might be ok. you might gets leaks and binding of the bearings, best to replace as a set.
I might just leave the kick shaft out and plug the hole in the cover and use the electric starter.
If your engine and frame number match and you absolutly have to have them match, then the weld and rebore is the way to go. I think that replcing the cases may be the cheaper way.
 
I searched XS400 engine cases and found them starting about $25. Take a look. Even at $75 shipped will be cheaper than a weld and bore.
 
Ebay item number 190342373954 80 Buy it now $24.99, item number 190342373443 78 buy it now $24.99. There are a 77 at $35 and a 79 at $45.
 
77-80 will work.
I believe 81-82 are different.

Very Handy Link Great for cross referencing.

I know the part you're talking about. It can be fixed but I've heard it'll break again in most cases.
 
crackedjournal.jpg


and that helps a lot thank you very much
 
Yeah, that's the damage I expected. Engine was seized, and someone gorilla'd it. Neither the first, or the last.

I'm an unwilling XS400 expert, and you'll soon be one too. I would suggest a bottom half off ebay, or craigslist. I know there have been a bunch suggested.

If you have any question's don't hesitate to ask. I've been down the XS400 road, and I live 20 minutes away. Not to mention I changed a hot water heater at my dad's house off 183'rd, and 84'th ave yesterday.
 
thanks man i live in the townhouses in brookside glen off 88th avenue and 191st im slowly becoming one also. unfortunately its before its running lol. ill definitely be asking more questions. but it will prob be in my build thread. so just check that. and thanks for the help everyone. it helps a lot
 
Ebola can you use mismatched cases on a 400? It's not recommended with the 650. I think for $24 I would use a matched set.
 
I'm honestly not sure. I was being sarcastic when I said expert, just learned a lot going through all of the BS on my wife's 400. Not as much of a knowledge base on them as there is on the 650's so I had to learn more the hard way. Honestly it's a really easy bike to work on, and is about as simple as they come.
 
Would that 1980 special II engine case work? i assume the special is just a cosmetic designation? my block number is 2L0 - 106053 a have discs front and back. rectangle taillights and my side covers say xs 400. i thought the special II's had special on the side covers but i may be wrong. i have no idea options package i have, but im pretty sure that its a xs400F based on yamaha motors online manual. any help?
 
Not found alot of information
But from what Ive found your motorcycle would appear to be either 1978 XS400E or a 1979 XS400F
As far as the 1980 crankcases are concerned, part numbers for 1978, 1979 & 1980 XS400 crankcase are all the same (1L9-15100-01-00)
Hope this helps a bit
Kev :thumbsup:
 
Hey all,

New to the forum and I have been trying to get this info myself as I have the exact same problem as Volcom. But my question is realy this: What year is my engine case? (3F8-030299) is the number but I cant seem to find any charts or numbers matching to that set.

Oh BTW the only component I have is the engine itself. No frame, bars, lights, yada yada yada. Engine only and was thinking of starting a small cafe project with my cousin.

Anywho, any information concerning the year and model would be great so that I can start this thing on the road to recovery.

Thanks

CBass
 
Hey all,

New to the forum and I have been trying to get this info myself as I have the exact same problem as Volcom. But my question is realy this: What year is my engine case? (3F8-030299) is the number but I cant seem to find any charts or numbers matching to that set.

Oh BTW the only component I have is the engine itself. No frame, bars, lights, yada yada yada. Engine only and was thinking of starting a small cafe project with my cousin.

Anywho, any information concerning the year and model would be great so that I can start this thing on the road to recovery.

Thanks

CBass

from the yamaha owners club forum

XS400-2E 1978 400 XS400-2 Street 2G5
XS400-2F 1979 400 XS400-2 Street 2V6
XS400D 1977 400 XS400 Street 2A2
XS400E 1978 400 XS400 Street 2L0
XS400F 1979 400 XS400 Street 2L0
XS400G 1980 400 XS400 Special 2 Street 3F8
XS400H 1981 400 XS400 Street 4R5
XS400J 1982 400 XS400 Maxim Street 12R
XS400K 1983 400 XS400 Maxim Street 12R
XS400L 1884 400 XS400 Maxim Street 15G
XS400RJ 1982 400 XS400R Seca Street 16M
XS400RK 1983 400 XS400R Seca Street 16M
XS400SG 1980 400 XS400S Heritage Street 3F9
XS400SH 1981 400 XS400S Heritage Street 4R4
XS400SJ 1982 400 XS400S Heritage Street 14V
 
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