The Mule: '77 XS400

[scott s]

I knew the bike had exhaust leaks, so I ordered some new gaskets. The RH side went on fine. On the LH side I found this:



The P.O. had already stacked two gaskets in there.



Hmmm, it looks like he welded a nut onto a smaller stud. No problem, lets just back it out.
Nope. About 5 lbs. of torque and....

 

[scott s]

No problem. We actually have a spare stud on hand. We'll just drill this out, remove it and fix it properly.



Except, A) our bits are dull, and B ) the stud seems hardened...maybe from the welding.
We had to stop for the day, but it WILL be fixed properly.

 

[bcware]

Time to drill it out and tap new threads. I had to do this before

I have also found the hardware on this bike to be very difficult to drill. It's super hard.

 

[xschris]

It's nice to see your fixing it the right way

 

[scott s]

While this will have to wait...



...I did get the tumbler swapped in the gas cap. It works properly with a key, now.

 

[DARKMIDKNIGHTWARRIOR]

Scott S What kind of seat pan/ tail is that? Did you make or buy? Please and thanks.

 

[scott s]

It's a metal seat pan. The P.O. made it and it's actually pretty cool. Fits nice and has great lines. The tail light is built in and tucked under the rear. I really dig it.

 

[scott s]

Man! That exhaust stud is hard! We're going to try with a carbide bit, soon. I really hope to not have to pull the engine and, especially, the head.

 

[bcware]

I believe I got one of those out with a very small cobalt bit. Just be careful. The harder the bit the more brittle it is. Too much pressure will snap it like a tooth pick and you're out like $7 for that tiny bit! I had no success starting with anything even close to the size of the stud. I went very small to start.

 

[scott s]

The kicker was just sitting on the....shaft? Whatta ya call that part?

Anyway, it was cheaper to order the missing parts from Partzilla than to get a used kicker.



All fixed up and works properly now. I wrapped the end with hockey stick/batters tape.



Notice the oil on the clutch cover? I was half expecting to find a bad kick shaft seal, but luckily, in a way, it's just a broken dip stick cover. (crappy pic...sorry)
Anyone have a good oil dip stick they'd sell me?

 

[scott s]

Also started working on the tach mount.



Epoxied the floating screws in the tach housing (hate those things...) and gave the bucket a quick shot of paint...

 

[scott s]

Still have to do a little final grinding and paint the bracket, but there she is.

 

[scott s]

Gonna load her up in the van today and take her to a local shop. We can't do anything with the exhaust stud and they said they can get it out, even if they have to put a TimeSert in.
Stay tuned....

 

[xschris]

Good progress Don't forget to remove that plug over you crank case breather tube and put a hose on it to your H-pipe

 

[Sesty]

good luck on the dipstick! when i was searching for one i found people were selling the whole cover plus the stick for cheaper than the people selling only the dipstick.

 

[scott s]

Good progress Don't forget to remove that plug over you crank case breather tube and put a hose on it to your H-pipe

On my To-Do list. I have a breather tube, just waiting to get to that point.

 

[scott s]

Finally got the bike back and the exhaust stud is repaired! Got the pipes installed and took it for a short test run around the neighborhood today.



I need to put a few test miles on it for Pamco Pete so he can evaluate the prototype Pamco ignition. After that, I can take it down for brief periods to address a few things:

-sort out and neaten up wiring.

-address an oil drip from the drain plug....I think the washer on there isn't actually a crush washer.

-Get tabs welded on to mount proper rear sets. The GP shift pattern is easier than I thought, but the current rear brake is just a suggestion.

-"pretty her up" a little bit.

 

[xschris]

It must feel good to finally ride it

 

[scott s]

I got about 45 minutes in on her today. I gotta say, that little %*@#er RIPS!

The ergonomics are awful for me. I'm 6'1" and 180 lbs. I'm already in contact with a forum member about some handle bar risers so I can replace the clip-ons with Clubmans. That, and getting some actual rear sets (and a working rear brake!!) will really help matters.

It needs a little work, but I can handle it. I just need another couple of hours of ride time for Pete before I can tear into it too much.

 

[scott s]

Well, between header wrap and exhaust leaks, this is what happens.



The P.O. really did a number on the pipes, too. They were a combination of stock head pipes, muffler shop tubing and poor welds.