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Skillzmans XS 400 Cafe build...yep another cafe!!

Discussion in 'The Garage' started by skillzman1, Dec 8, 2010.

  1. good to know about the cdi...I have a tray built under the seat...everything should fit...but will have to assemble someday to find out.
  2. hard to believe I dropped the ball on this project for almost a year now...but I sold my 84 honda sabre and ordered a bunch of new parts to start finalizing this thing.
    new tires,directionals,brake parts,carb jets and screws...working the body work details out this week hopefully get it painted shortly....we'll see.
  3. New tires/directionals and caliper piston came in today...removed rear from bike..dismounted by hand/remounted and reinstalled in 45 minutes ...not bad for a rusty old man with one tire lever.

    for what its worth theres a company on ebay selling stainless caliper pistons for these yamahas for $29 usd...only place I could find them...he doesnt list it as an application for the rear on a '77 xs 400d..but some measuring found the rear is identical to the front on the 77 and its the same as the 81 and newer front calipers.
  4. Todays progress
    1) clean/rebuild/install carbs with new pod filters
    2)install new plug wires and boots
    3) rebuild rear caliper
    4) mount new front tire
    5) put the bare metal tank in epoxy primer
    scored a left side brake caliper setup for the front for free..so I'll have dual front discs!!
    I like free upgrades!!
    tomorrow will be header wrap day...going 2" titanium wrap scored a 1/2 roll for free..auto supply store has rolls for $22.
    getting closer to making noise!!!
  5. gentlemanjim

    gentlemanjim More Wrenchin than Ridin

    We need pictures - PLEASE!!!
  6. liam

    liam XS400 Enthusiast

    Pics pretty please!!! Its like a fire without heat, im freezing to death but I cant look away.
  7. aint much to look at...but I'll see what I can do!LOL
  8. heres a few dirty teasers for you pervs out there!lol

    gsxr rearsets
  9. gentlemanjim

    gentlemanjim More Wrenchin than Ridin

    You're making me proud - Vey nice work.....
  10. Thank you...got some buddies that have cafes built,or in the process,and have been doing mini build days with some help...got to get this thing buttoned up...I think I'm maybe a solid day away from getting a test fire.....minus the paint work of course.
    still have to figure the seat mount,finish the wiring harness location and hookup,plumb the brakes...lots of little stuff..but evrybody helping along gets things done faster...would like to have it ready by the end of May....actually by 5/19.

    5/19 is the day my Dad died a few years ago...its been my 'race' number ever since...and its going to be part of the paint scheme on this bike...so that would be a good roll out date...but doesnt have to be.
  11. So headers are wrapped....got the left side front brake equipment waiting to install.

    FWIW...my buddy had an early 80's 550 virago he was scrapping...the left side front brake caliper and bracket are a direct bolt on to match the right...and I bought a rotor off ebay for $20 delivered...along with an 05 r6 front brake line which should be here shortly so the front brakes should be squared away by weeks end!
  12. volcomskater77

    volcomskater77 XS400 Chopophile Top Contributor

    looks good man. been awhile since i saw you on here. lol
  13. thanks ...I been slacking off for a year...dont know what I was thinking taking a punch the clock job and working 65hr weeks for 9 months?!?!?!
  14. dO-bOy

    dO-bOy Woohooo!

    What happened to the front fender? It looked really awesome and exactly the look I want. Is your a cut down stock front Fender it from a different bike?
  15. volcomskater77

    volcomskater77 XS400 Chopophile Top Contributor

    i can see the paint now! lol looks awesome. and that satin mac 2-1 with the chrome megaphone looks killer!
  16. front fender is in the corner with the gauges waiting for finish primer...which will be tomorrow....2k urethane primer on everything tomorrow...the wet sand and start laying paint scheme....still have to sort the seat a bit...but its falling inline.
    worked on it after work tonight...got the left side front brake stuff painted and installed..maybe some pics tomorrow as well.
  17. dO-bOy

    dO-bOy Woohooo!

    Care to share the source of the fender?
  18. stocker cut down....shaped on a bench grinder...rough ot up good with 60 grit on the chrome..epoxy prime..do the light filler if necessary..reprime and paint
  19. well due to the summer work schedule..I had to call in the pros.
    Got a vintage resto bike mechanic buddy coming over next weekend to do the wire and fire for me..get the tuning brought around to a rideable setting.

    Got the final prime on everything yesterday...wet sand and start laying the basecoat as soon as the new spray gun gets here.

    Might actually be able to ride this someday.....was hoping for 5/19...we'll see.

    5/19/12 will be 4 yrs since my father died at 58yrs old.....he used to bust my balls in fun about my dirt bike riding/crashing (can still hearing him chuckling.... R.I.P)....the week he died I adopted '519' as my race number...and this will be incorporated into this build as well...would be nice to have it done by then...at least I hope to get the paint on by then.

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