1. Want an XS400.com t-shirt? Go to the store to order. Limited sizes and quantities available.
    Dismiss Notice
  2. Hey Facebook people... We've created a group for XS400.com members to connect. Check it out!
    Dismiss Notice
  3. Dismiss Notice

Dutch '78 cafe build

Discussion in 'The Garage' started by bossink, Feb 1, 2015.

  1. Hi all, I just got my first project bike, a '78 XS400. I bought it for only € 100,- so I didn't have any high expectations. The bike wasn't running and I just had to believe that the previous owner put the bike away with a functional engine.

    My plan is to build a cafe racer style bike and learning something about bikes whilst completing the project. I've been riding for about 5 years now but have no real experience in maintaining or modifying a motorcycle. I think I do have some technical insights, and got some good tools (compressor, airlift) so I can only blame myself if things don't work out! :thumbsup:

    So,what did I buy?

    [​IMG]

    This is how the motor was found, partly disassembled but with all parts complete (I hope)

    I've just spent one night cleaning only the front chainwheel compartment.....one big clogged black mess! Hard to believe the thing could actually roll!







    [​IMG]

    Whilst sorting out the crates of parts I found these two beauties:

    [​IMG]

    [​IMG]

    Well...What do you think, will this get me a functional bike?

    [​IMG]

    [​IMG]

    [​IMG]


    Meanwhile I've taken out the rear wheel and saw if the electrical parts where complete. I think I'm almost complete but not sure yet. I am sure that I won't need all the electrics because I will leave the turn signals of the bike. Maybe go with a battery less setup?

    I've also tried to fit the carburators (tight fit when the intake rubber is cold!) but they are in no way complete. I seem to miss the mounting plates, the idle screw, some parts to make the choke work... *getting the shopping list updated*

    I've decided to strip the bike almost bare, but leave the engine in the frame for now. So, worked on getting the front forks out and the handlebar off.

    (got some issues with the airlift....)

    That's it for now, will keep this thread updated!

    Please let me know your thoughts!
     
  2. Looks like you've got the basis of a nice bike there. I really like the colour scheme.

    I remember being your age and having the energy to work as fast as you do in your videos.:D

    Looking forward to seeing your progress.
     
  3. Thanks for your comments Lyle! Not sure what to do with the color yet. The previous owner spray painted the side black without disassembling anything so I will probably take of most of the black parts and prep them for painting. I also like the blue scheme.... Black and blue should make a nice result I think.
     
  4. xschris

    xschris miles of smiles =)

    Welcome to the forum:)
     
  5. Requiem

    Requiem XS400 Addict

    Welcome! :)
    You snatched that bike from right under my nose hehe
    Wanted it for spare parts and the engine as well :)

    Good luck
     
  6. Ahh...too bad ;) maybe if the project doesn't work out I will let you know! :thumbsup:
     
  7. Update:
    Got the fork legs cleaned and polished.

    [​IMG]

    Got most of the dirt of with various brushes, brake cleaner, degreaser and rust remover.
    As you can see, this dirt has been sitting here for some time now...

    [​IMG]


    I just used a steel brush on a battery powered screwdriver to get rid of most of the corroded and damaged top layer.
    Then, I took some steel wool and a bit of wet sandpaper and got my hands dirty.


    [​IMG]

    [​IMG]

    I grabbed some Coca Cola in stead of water because of its rust dissolving capabilities. (and it was just next to me in my mancave-frig :) )

    [​IMG]

    After that, I used S100 and a polish disc to buff up the fork legs.


    [​IMG]

    [​IMG]

    [​IMG]





    I'm pretty happy with the result! Looking great if you compare them to their previous state imho. And, let's face it; it's a bike from '78...it needs some imperfections :thumbsup:

    I'm going to look for a table top grinder to fix the polishing discs to. The battery powered drill works, but you'll drain the battery pretty fast and it's a hassle to get it in a vice. And I'm sure there's more polishing to be done!

    See ya!
     
  8. levdir

    levdir Rounded bolt brigade

    Those look great, good work!
     
  9. Well well.... it's been too long....

    I'm going to revive my project after too long doing nothing. In the meantime I've put my XS in all 4 corners of the garage to make room for the other projects. This winter is XS400 time!

    Looking forward to share this revived project with you all!
     
    drewpy and BBS360 like this.
  10. Working on preparations first:
    Step 1: Installing an old wood burning stove in the workshop so I don't freeze this winter ;)
     
  11. Bart-Maxim

    Bart-Maxim XS400 Member

    Nice to see there a some fellow Dutchies out here! All tough we are working on completely different models they're all xs400's in the end right. Very curious on what all the outcomes will be!
     
    bossink likes this.
  12. Update:
    • Created a bit of extra workspace with some power outlets on the wall and overhead
    • Installed a Raspberry PI to have immediate access to the forums :thumbsup:
    • Pulled off the tank (which has two small holes) for a colleague to repair (thank you!)
    • Ordered a cordless Dremel multitool
    [​IMG]
     
  13. Bart-Maxim

    Bart-Maxim XS400 Member

    The XS400 from Ellaspede thats good inspiration right there man! ;)
     
    bossink likes this.

Share This Page