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I couldn't stay away... XS400 Heritage special resurrection

Discussion in 'The Lounge' started by JPaganel, Aug 22, 2020.

  1. JPaganel

    JPaganel XS400 Addict Top Contributor

    Do you suppose this gas cap seal is due for a replacement?

    Yes, yes it was.

    Shined up the metal, greased the latch, replaced the rubber.

    Attached Files:

  2. JPaganel

    JPaganel XS400 Addict Top Contributor

    Took it out for a spin around the block. The front had a weird rhythmic thing going on. Took the wheel to a shop I frequent.

    Shop guy was like "That looks like a wheel off your free bike". And then, once he put it on a truing stand - "Holy shit".

    So, the rim was shot. I ebayed a wheel for $60, which is hella not bad.

    I also decided to get a centerstand. That would make all this stuff easier. Went to put on the centerstand. Had to pull the muffler for that.

    In the process of pulling the muffler broke two exhaust studs. Welder to the rescue.
    Old studs out, new studs in. Exhaust back on.

    Meanwhile the wheel showed up. And then, suddenly, the plate.

    So, lo and behold, it is street legal.

    Made a parts run on it today.
    20210626_215854.jpg 20210627_204333.jpg
  3. bigdog

    bigdog XS400 Enthusiast

    Is that the end of the story? You've done an amazing job of taking a dead bike, that was just about ready for the crusher, and making it run. I wouldn't have known where to start or where to go next..I don't even understand some of the things you've done. But you've obviously enjoyed it. Just wish I had those skills. Hey, if you ever fancy a free holiday in sunny Manchester, in the UK, I have an XS that could do with your help. Beers on me.
  4. JPaganel

    JPaganel XS400 Addict Top Contributor

    Almost. I have one more mechanical thing to do - I need to replace the seals on the butterfly shaft in the carbs. I have an odd wandering idle happening, and those seals can do it.

    Past that I might start on things cosmetic. A little paint here and there, maybe get a less ugly muffler.

    Aw, yer gonna make me blush... :D

    This is really probably more work than it was worth, but sometimes you get into stuff like that as a challenge and toss reason in the wind.

    Manchester could be fun. Never been to anywhere in the UK yet.

    Now look at who is throwing away all caution... :D
  5. Looking forward to seeing what else this bike has in store for it.
    JPaganel likes this.
  6. JPaganel

    JPaganel XS400 Addict Top Contributor

    I redid the throttle shaft seals. That seems to have corrected the wandering idle and vastly improved starting.

    Robsteeler66, xschris and CaptChrome like this.
  7. bigdog

    bigdog XS400 Enthusiast

    Well it's been a while since I've perused this forum..and yes, I am ashamed. The reason is because my XS400 custom/rebuild/thing ground to a halt a couple of years ago. I won't bore you with details. But this thread has just popped up in my mailbox and I can remember following it with interest.
    So well done mate, yer bike is running pretty much like it should. All that effort has paid off.
    Now, like I said a couple or three years ago, there's an endless supply of British ale just waiting for you, should you wish to repeat your magic on my bike.
  8. CaptChrome

    CaptChrome XS400 Addict Top Contributor

    @JPaganel - sounds great!

    A couple of questions for you: did you loctite the new butterfly screws on the shaft when you went back together? I will be replacing these seals in short order, and am thinking of using loctite rather than trying to peen the new screws, so just wondering how you went about it.

    I didn't realize you had a MAC exhaust on the bike. Any issues with fitting the center stand back on the bike or with the headers rubbing the engine mounting tabs on the forward lower frame? I appreciate any insight.
  9. JPaganel

    JPaganel XS400 Addict Top Contributor

    I didn't. They were kinda tight going in, and to be honest, I just forgot. We'll see if that bites me.

    No problem with the stand.
    The exhaust is up against the tab, but it's been that way for a long time. I don't really see an issue.
    CaptChrome likes this.
  10. CaptChrome

    CaptChrome XS400 Addict Top Contributor

    Great info - thank you for that. On the carb butterfly screws, the factory peening may have left the threads in the shaft somewhat deformed and that may be to your advantage. In my mind, to re-peen the screw ends would require making a jig to support the shaft while hammering inside of the carb. That is not something I want to deal with as the potential to do harm is pretty easy. I also don't like thinking about getting a Dremel inside the carb and removing the old deformed screw end. I will see how it goes with mine try at it.

    Well, I guess fitting a center stand is still in my future!
  11. JPaganel

    JPaganel XS400 Addict Top Contributor

    I didn't actually remove the peening.

    I just unscrewed them, and it pulled out.

    I would not go hammering on the shaft either.

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