Petew XS400 brat scrambler build

I did a cylinder hone to polish them a touch, cleaned the carbon from the combustion chambers and piston, did a valve lap. I resealed the entire engine except I did not split the cases or remove the rocker assembly as no wear showed. I had new rings but didn't use them as the others look great and measured to spec. Basically, I bought an overhaul gasket set for $35.00 and the rings I bought for 26 dollars will go into the other motor when it gets done,
I also went through the carbs.. I am not so sure about "easier" than cars...most cars have a lot more room to work with. I worked in auto repair field for 20+ years and felt quite capable there....this was a learning experience. The next one will be easier.

 

Nothing to update Spectra,still sitting waiting to get put in. Busy music schedule the past 3 weeks. I walk by it daily and wish i had more time ( and an extra set of muscles) to get it done. I did wire up the new spade fuse box and make a new front brake cable. Hopefully Tuesday or Wednesday next week it will fire up. I also ordered a set of Uni air filters while I've been waiting and started to overhaul the second set of carbs....time, money and muscles, things I wish I had more of!

 

That's the goal! If not I fear my imagination will start me thinkin'....I have my second one waiting for over the winter!

 

...and my brother just bought a welder...I'm going to try and learn how to use it. You know what kind of fun THAT can bring about!!! Bobber style next...

 

....and my new filters showed up today. ON virtually everybodies recommendation I ditched the Emgo cones for a set Uni's. Motor goes in tomorrow and maybe running by Thursday! I am stoked. While I have been waiting I can't stop shopping for upgrades. I am looking at adding directionals after all...we'll see. I am still fighting myself about tires . Mine are the 16 rear 18 front spoked wheels and I can't decide between a street tread or a trials type tire....damn, this gets hard sometimes!

 

Thanks to my younger, and stronger, brother I have gotten the motor back into the bike. Tomorrows the day to finish installation and wiring. With luck there will be a running XS400 in the driveway. I have also decided that directional signals might be a good thing to have so I ordered 4 low profile blinkers that shouldn't alter the look too much. Once I have it running I can go about hiding what I want hidden and upgrading what needs that. Tires next...

 

I decided today that the headlight ears didn't fit the look I wanted, I ordered a new set that will compliment the blinkers nicely, gives me a chance to neaten up the nest of wires in the headlight housing. I also painted the lower fork tubes black and added my pinstriping to the tank. My phone is on the fritz so I don't have any pics...yet! Overall I am pleased, just concerned at this point about the shifter. I am conflicted as to whether to fill the bike with oil and give it a go after starting it or pulling the cover off and checking clutch/shift pawl...we'll see.

 

Ready to start, I thought....something electrical is not connected correctly. Time to trace and test!

 

The cause of the no crank was a bad ignition switch, Some place along the line I had lost the key that went with the bike. No problem, I had a perfectly good switch sitting on my bench from another '80 G. I swapped them and proceeded on with my wiring etc. On a chance I had a new key made for the original cylinder after I had exhausted all the other possibilities. Along with the no crank my rear light would go out when I used the brakes...I was clueless A wing and a prayer they say...I switched out the cylinders and I get all functions and it will crank over. I will spend some time charging the battery and reassemble what I have taken apart and hopefully she will fire off...so close now I can taste it!

 

It was soooo frustrating. I went over every connection, traced on the schematic, tested wiring . It cranked like a son of a bitch before teardown! Finally I looked at the pieces I replaced. New starter solenoid,blinker relay and ignition switch, it was the switch/cylinder that was bad.
....feel like a dumbass for losing the key in the first place. How is yours coming along?

 

Battery needs charging and it's raining here...I'll wait and see.

 

Got new headlight brackets installed along with low profile LED blinkers for the front and rear. Picking up a new battery today, discovered that the one I have been using drops off so much under load it is a wonder that it cranks things over at all. I can get 1 cycle through before it goes dead. I am hoping that this is the final step, outside of tuning and synch'ing the carbs, and I will be able to get a few days of riding time. I know the bike's battery is missing, I was trying to show the blinkers and headlight mounting...