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Petew XS400 brat scrambler build

Discussion in 'The Garage' started by Petew, Jun 14, 2017.

  1. Petew

    Petew XS400 True Believer Top Contributor

    If you have read any of my prior posts it is clear to see that I am pretty new to this bike wrenching stuff. I have the desire and the time so I decided to get after a coupple of 1980 XS400's I had sitting around for the a few years. They had been something I planned on doing but a major surgery after an aortic dissection I suffered monstrous bout of vertigo and decided that bikes weren't the best choice. Time has past and so has the vertigo . i am retired and decided that I needed to occupy my time. I had 3 frames to chose from and i went with the cleanest of the 3. I have removed the engine to freshen it up and check it out. I decided today was time to start mock up...The tank was painted like that when I bought it, the bars are MX set that my younger brother had and I removed the cluster to ready it for a mini setup. I chopped and shaped the seat as a temporary solution. I have yet to shorten and shape the rear fender...
     

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  2. spectra

    spectra XS400 Junkie Top Contributor

    Looks like a great start! Will be watching to see how it goes.
     
  3. Petew

    Petew XS400 True Believer Top Contributor

    Today I was able to the some time to inspect some things. I have an obvious problem with the rectifier and it will need replacement. I am tempted to just do a reg/rec combo unit to clean up the battery area. I am using stock air cleaner boxes on recommendation from a friend. I am beginning a clean up and overhaul the carbs as needed and cleaning up some ratty looking parts. I tested the engine that I removed and the crank spins nicely with good compression so I am going to put it back in the bike as a e-start only. I will also be using a fullsize battery and stock battery box. I feel like the progress is going well, from selling a broken bike for cheap to repairing and rebuilding it into something I will want to keep! It is pretty exciting!
     
  4. Petew

    Petew XS400 True Believer Top Contributor

    Cleaned parts again, clean carbs up getting ready for o/haul, I bobbed the seat for scrambler look but I moved on already. Cleaning parts for a day of re-assembly.
     

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  5. Petew

    Petew XS400 True Believer Top Contributor

    Removed seat brace from frame and modified the inner plastic shield so it doesn't interfere with mock up.I am keeping it to somewhat shelter the electronics that i have coming. I cut a mock-up of the seat pan and began to find the perfect location for the fender-which I will shorten.I realized today that the front blinkers have shorter stalks than the rear by an inch or so. I have a spare set of fronts so I will use them to "tighten up" things at he rear I opted for keeping the signals at this point. I am waiting on fork gaiters at which time I will also flip the headlamp mounts to lower the lamp on the forks. I am also toying with dropping the forks by 2 inches, I have short legs!, but I want to see what it looks like first.
     

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  6. Petew

    Petew XS400 True Believer Top Contributor

    Still waiting parts...Decided it is time to do some of the "other stuff". Stripped finish off my tank that I am going to use.Bobbing the front fender. kind of like the raw look of the tank...tempted to just clear it and leave it...
     

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    Last edited: Jun 21, 2017
  7. Petew

    Petew XS400 True Believer Top Contributor

    Meanwhile, I am getting the second frame ready to go to the welder... Another 1980 400 frame...haven't decided how far I'm going with this one yet.
     

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  8. spectra

    spectra XS400 Junkie Top Contributor

    What were you thinking ?
     
  9. Petew

    Petew XS400 True Believer Top Contributor

    I am using it as a transfer medium. I have title to this frame and a complete bike with no title. I will probably go with a brat style or possibly a tracker. I would do a cafe racer but I don't care for the seating position of them.I want something pared down and individual. I would love a hard tailed bobber but where I live in Upstate NY the roads are not conducive for someone with back and joint issues.
     
    Last edited: Jun 22, 2017
    Aero likes this.
  10. Petew

    Petew XS400 True Believer Top Contributor

    Made some progress today. I added fork gaiters and dropped the forks about an inch. Did front brakes and installed shortened fender.I reversed the headlamp ears and dropped the lamp down. I have decided on a white tank. I kept the flamed one around for the project. This is where we stand now. Ready to put in the motor as soon as some parts get here and I can finish it up.
     

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    Chance and Jeff0133 like this.
  11. spectra

    spectra XS400 Junkie Top Contributor

    Looks good so far. I kind of like the white.
     
  12. Petew

    Petew XS400 True Believer Top Contributor

    Thanks, I have a plan for it that involves a little color. I am waiting for the seat so I can fab the rear fender and lights. It has been an adventure so far. I have found out that diligence and patience are the biggest factors in dealing with these old bikes.
     
  13. spectra

    spectra XS400 Junkie Top Contributor



    Patience :lmao: hell I have no time for that................................

    I am waiting to and it sucks..........down to the frame and waiting for a seat also........I have a bunch of frame work to do but that's easy to me. My biggest concern is the motor......it ran but.

    Ordered a new throttle that I found and well got this email............its on backorder and comes from Italy..........oh great.

    Keep on posting pics I like to see what people are building.
     
    Petew likes this.
  14. spectra

    spectra XS400 Junkie Top Contributor

    Have you thought of tires or keeping whats there? I have been searching for some that are a little more aggressive and well no Bueno so far...........doesn't help I am a newb and well tire sizes make my head hurt........
     
  15. Petew

    Petew XS400 True Believer Top Contributor

    I think I have found a set of Shinko 712's that I like. Same size as what is on there now. I am opting for handling and street-ability over "look" because II haven't found a trials tread tire I like within my measly price parameters. Check RevZilla.
     
  16. spectra

    spectra XS400 Junkie Top Contributor

    Yeah wanting a little more aggressive tread design on my end. Thats what is killing me I think.......I really like the Kenda K761s but the sizes are just not there.

    Do you have an 18 and 16? I am looking for 18s on both ends.
     
  17. Petew

    Petew XS400 True Believer Top Contributor

    Yes, I have an 18 and a 16.
     
  18. Petew

    Petew XS400 True Believer Top Contributor

    Finally got a day when I had some parts and some time. My younger bother came up and help me set the engine in the frame and get it bolted in. I had already finished bobbing the frame end and cutting of mounting tabs so I was able to fit the seat properly.. I replaced the broken brake handle and perch and repainted the clutch lever and perch so they match. I have begun to relocate the ignition switch to clean up the front forks. I will install a mini speedo as soon as the bracket gets here. I need to finish the wiring and put on the chain, hang the exhaust back on, and it should be time to fire very soon.Still waiting on some more parts but I am seeing the end of the road finally. I am so glad I went the way I did, parting this out would have stopped me from an awesome learning experience!
     

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  19. spectra

    spectra XS400 Junkie Top Contributor

    Coming along nicely...........where did you get the seat from?
     
  20. Petew

    Petew XS400 True Believer Top Contributor

    I oredered it from eBay. I originally planned on chopping down the factory seat, did it and hated it. Started scrounging materials to build my own and came across this for under 40 bucks. I will be making the seat for the next one but this was a very cheap way to go. I had to trim back seat tabs and drill a couple of new holes in some tabs but altogether it went on pretty easily.
     

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