Introduction and Advice Needed, for 83 maxim XS400

@Addison ya that's it!

 

Happy NYE everyone!

I'm back with a couple questions about my next step in my first motorcycle project. The topic of this post is Carburetors!

First question. I plan to run a cut off exhaust with "hi flow" mufflers. I've seen folks on this forum and others say that running a free flowing exhaust will necessitate a re-jetting of the carbs. I would imagine that means running a larger jet size?

Second question. I purchased 2 carb rebuild kits from mikexs.net a while back. I'm wondering if I need larger jets, are they included in the kit? It seams to have a bunch of jet options available. Pic of what the kit contains attached below.

Third Question. If anyone has any advice, links to "how toos" or sweet step by step instructions/videos on carb rebuilding, SEND THEM MY WAY!! I have the service manual on hand, but any other tips n' tricks would greatly be appreciated!

Thanks!

 

Back from the thread graveyard of page 3....

It's finally starting to feel like spring here in Chicago! And that means I can finally try and get this bike started!

Thanks to everyone with the advice on how to winterize my ride a couple months ago, but now I need tips on "un-winterizing" this beast. Below is a punch list of items I could use some advice with...

- I fogged my motor before the winter. Are there any extra steps to "un-fog" the motor?
- I got new oil filters from MikesXS.com but they didn't come with filter casing O-rings. I should be able to bring the old o-ring and casing into a parts store and find a new one, right?
-The handbook says I should use 20w-40 motor oil on for my bike, but I can't find that weight oil anywhere! Is 20w-50 ok? Also my sight glass is pretty FUBAR'd and being a super cold start...does anyone have a round about idea of how much oil should go in the crank case before a first start?
-I need new fuel lines. Any idea on the size line I need? I need to make sure I get the right size line and fuel filter combo
-can someone please send me a pic of the start/kill switch controls on a 83 Maxim 400XS, time has not been nice to mine and I can't read them. I don't wanna be that guy thinking his bike is broke when the off switch is on...

Besides that do any of y'all have advice on starting a bike that hasn't started since at least last summer?

Thanks!

 

Thanks so much Warren!!! Once I get this beast started I can get a start on the building it up, I'm sure it'll be an adventure lol

 

Welp I got the bike started and it purrs like a kitten. Took a long while to get it to warm up, but I'm sure that normal for a bike this age that hasn't started in god knows how long. Check out the video below!



After I let the bike warm up a bit I checked on the status of the drivetrain. I pulled in the clutch and kicked down into 1st gear, and as soon as I did the back wheel started spinning, even with the clutch handle compressed. I kick it up into 2nd-5th and it just spun away even within no clutch applied. I'm sure this isn't normal right? I got a feeling that something with the clutch is fubar'd. Anybody got any ideas on what it could be?

Another thing is my petcock is leaking pretty bad. Do y'all recommend using a rebuild kit or just buying a new one?

All and all it feels good to get it started so I can move on to the next task of this project.

 

Unfortunately there will be no test rides anytime soon. The brakes and tires are are roached! I'll study up on the clutch adjustment tonight, thanks!

 

Thanks Mike!

Got an advice on a leaky petcock?

 

I ended up replacing the vacuum driven petcock with a gravity style one and it looks as if the leak is gone!

I'm looking to replace my choke cable and assembly and cable with a pull type located on carb. Anybody got a clue if this is even possible?

Also the weather has taken a turn for the worse here in Chicago, so not much wrenching lately. But I have been ordering parts like crazy!

 

OK! So the nice weather is finally here in Chicago ...kinda (supposed to be below freezing tonight)... now it's time to start with the tear down and rebuild.

After I got the bike to crank over (which was featured in a post above) I figured I'd move onto the front end.

First step front end tear down. I had already stripped down the damaged headlight mounting brackets to make room.

Got the bike on a super pro center stand lol


Then the front wheel and fork tubes came out




After the front end was stripped it was time for the rebuild and refurbish

Luckily the fork tubes are in decent shape. The top plugs came out "easily" compared to some of the stories I've read on here.



also the oil wasn't in bad shape either. Hard to get a pic of how clean the oil was, but if you look at the drip on the fork tube you can kinda see



filled them with new oil and then prepped them for paint



paint drying, plus guest appearance of my dog Lucy



now onto the front wheel and brake rotor

I had to use some PB Blaster and rubber mallet to get the rotor off



prepped, taped and ready for paint







taped off and painted up the rotors with hi temp paint as well



finished wheel

 

Now on to the reassembly of the front end

You can't put freshly painted parts on some dusty a$$ yoke and triple tree, so on to more prep and paint


turned out nice!



now on to the instillation of the handle bars



now the fork legs with new gator boots are back on



Front wheel back on and bike back on the ground.


I also installed new fork mounted headlight brackets with during the install. The whole front end I'm in love with, but I go back and forth on the tracker bars.

Let me know what y'all think!

 

Dang! I'll edit the post!

 

Pics should be up! Had to dust off the old Photo Bucket account from like 10 years ago