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New guy building XS400 Softail Bobbers

Discussion in 'The Garage' started by Buddha, Jul 4, 2021.

  1. Buddha

    Buddha XS400 Addict

    Yeah I hear what you're saying. I had to let the paint sit a couple of days to sand with 2000 grit to get rid of dust nibs and some texture before applying the clear coat. Time will tell on longevity. If I have to redo it no big deal, it's less than a $50 base coat and clear coat material cost.
     
  2. JPaganel

    JPaganel XS400 Addict

    I am convinced that being in the Midwest is a +5 modifier to dad jokes.
     
  3. Buddha

    Buddha XS400 Addict

    LOL, I was thinking about you today JP.
    Not only did I make my rear brake assembly pretty, and also made it mechanically sound with new shoes and cleaned and lubricated brake cam.
    IMG_2916.jpg
    IMG_2917.jpg
     
    Spitfire_X24, Scotty4 and JPaganel like this.
  4. Buddha

    Buddha XS400 Addict

    Made it out to the shop today for a bit. I knocked off a small project that was bothering me, the exhaust system.

    This '80 build has the welded on mufflers and cross pipe. I've read the posts about not cutting the OEM mufflers off.
    I don't like to 'butcher' things but some PO did. You can see in the following 2 pics some PO cut the aft end of the mufflers off just past the cross pipe and welded on a piece of 2 1/2" exhaust pipe cutting an angled tailpipe. They also welded in a baffle with ~7/8" hole in it. The PO worked very hard at doing a very fugly job of this.

    Good example of a fugly job........
    IMG_2928.jpg
    IMG_2929.jpg

    So I said to myself "self, if man built it, man can fix it". I want to keep the upper and lower weep holes in the pipes functional.

    Upper weep hole.
    IMG_2926.jpg

    Lower weep hole.
    IMG_2927.jpg

    So I cut the mufflers off....................................................
    IMG_2931.jpg

    After measuring and scratching I found that I have to weld a piece of exhaust pipe1 1/4" long to make the pipe the same length as the '78 pipes. I also took the time to cut and form the inner exhaust pipe so that it will defuse the exhaust gases.
    IMG_2933.jpg

    The end result is attaching the aftermarket muffler to the pipes same as the '78 build while keeping the weep holes functional even though the pipes will be wrapped. I am confident the wrap will allow moisture to escape from the weep holes.
    IMG_2934.jpg
     
  5. Looking good Buddha!
    So nice, you're doing it twice!
     
  6. xschris

    xschris XS400 Guru Top Contributor

    10,429
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    Sad to see what the po did to what I think is the best exhaust setup for overall performance with these bikes. It's good your able to do something with them at least.
     
  7. Buddha

    Buddha XS400 Addict

    Yes it is sad, but I believe the exhaust will turn out ok.

    Over the last couple days I cut pieces off and welded pieces that were needed on the frame just like the '78 build. Then I degreased and depainted the frame.

    Installed nutserts for the battery box.
    IMG_2950.jpg

    Set up depainted frame for primer.
    IMG_2951.jpg

    Black primer applied.
    IMG_2954.jpg

    Couple of pics of final paint (3 coats).
    IMG_2955.jpg
    IMG_2956.jpg
     
  8. Looks great Buddha! What paint did you use?
     
  9. Buddha

    Buddha XS400 Addict

    I use Dupli Color Satin Black wheel coating, 3-4 coats over black primer.
     
  10. Buddha

    Buddha XS400 Addict

    Went out to the shop for a bit today. Got a couple of small jobs done on the bike.
    First was attaching the lower mounts for the rear fender.
    IMG_2959.jpg
    IMG_2960.jpg

    Then completed fabrication of the fender stays.
    IMG_2961.jpg
    IMG_2962.jpg
    IMG_2964.jpg

    Then I installed the All Balls cone bearings in the steering column.
    IMG_2965.jpg
    IMG_2966.jpg

    Then I did the obligatory mock up........that gave me the chance to introduce myself to the bike and see what kind of personality it has.....
    I think we'll get along just fine
    IMG_2967.jpg
    IMG_2968.jpg
     
  11. Buddha

    Buddha XS400 Addict

    Went out to the shop this afternoon, scratched a bit, then scratched some more.
    Then decided to finish up the engine O/H.
    Pulled out the Sioux seat grinding outfit and touched up the seats (the valves were ground over a month ago).
    IMG_2975.jpg

    Then I lapped the valves, installed new seals and assembled, couple pics
    IMG_2976.jpg
    IMG_2977.jpg
     
    Spitfire_X24 likes this.
  12. CaptChrome

    CaptChrome XS400 Enthusiast

    At the rate you are going, you might be able to get both bikes out for a tandem ride before the snow and ice put a lock on the season! It is going to be hard to tell these bikes apart.
     
  13. xschris

    xschris XS400 Guru Top Contributor

    10,429
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    Being just like the first bike, this has to be very easy now. Should take no time.
     
  14. Buddha

    Buddha XS400 Addict

    Don't tell wifey what I'm using her oven cleaner for......
    IMG_2984.jpg

    One degrundged and degreased crankcase after oven cleaner, water rinse, Spray Nine and brushing, and final water rinse.
    IMG_2985.jpg
    IMG_2986.jpg
     
    motoTrooper, Scotty4 and Spitfire_X24 like this.
  15. Buddha

    Buddha XS400 Addict

    Out to the shop for a bit today. Installed pistons with new rings and circlips, then the cylinders, and cylinder head cover - torqued all to spec. Installed all new gaskets and seals as required. Set valve clearance. Cleaned sump filter screen and installed new oil filter. All in all a good day.
    2 - 3 pics
    IMG_2992.jpg
    IMG_2993.jpg
    IMG_2994.jpg
     
  16. Buddha

    Buddha XS400 Addict

    Out to the shop again today.
    Put some engine paint on the 400. It's at the point where it's pretty well ready to install onto the frame.
    IMG_2995.jpg
    IMG_2996.jpg

    Then I scratched a bit, then turned my attention to the instrument cluster. Broke it all down to glass bead, buff, test, paint, install LED bulbs, yada, yada, yada.
    So I find that some PO, in their infinite wisdom, decided to completely remove the signal light indicator bulb, socket, and wiring:doh:
    IMG_2997.jpg

    Actually the complete wiring harness has been hacked up, oh well, just a bit more wiring work no big deal.

    So I happen to have some mini LED lights.
    IMG_2998.jpg

    Took a couple of them, cut a piece of rubber tubing the same size as the BA9 light sockets and inserted the bulbs.
    IMG_2999.jpg

    Then inserted this into the socket cord assembly, should work if's it hooked up right:cheers:
    IMG_3001.jpg
     

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