The start of something new

Patriot

XS400 Enthusiast
Messages
31
Reaction score
0
Points
6
Location
Portlandia
well this is how far I am after 3 days of trying to decide what to do with it... ended up going the cafe route... monoshock and all. The ridged frame I have was already cut in all the wrong places... PO! So I have taken the spokes and manual breaks and forks from the 80 Heritage and installed them on the 82 maxim frame.. I have a 77 Kawasaki tank to use now if I can source the right "BIG" headlight I should be able to get mockup done next weekend and paint on some parts. Looking forward to that! I will update as I move forward.
 

Attachments

  • 7-29-12 003.jpg
    7-29-12 003.jpg
    311.5 KB · Views: 475
  • 7-29-12 001.jpg
    7-29-12 001.jpg
    310.4 KB · Views: 469
OK... so I wasn't done!... A few hours later and I'm ready to start cutting and welding! Any Ideas as what to do with the exhaust??? I would like to keep it somewhat quiet... I start work at 3:30 am so I have to be considerate of my neighbors. Will probably put heat wrap on the pipes.. and would like to go 2 to 1 and diagonal out in front of the rear tire on the right side.
 

Attachments

  • mockup1 002.jpg
    mockup1 002.jpg
    305.7 KB · Views: 497
  • mockup1 004.jpg
    mockup1 004.jpg
    304.5 KB · Views: 625
so today was a big day.. cut the frame behind and under the seat...fitted the gas tank.. painted the frame and engine along with a bunch of odds and ends... still am undecided as to paint the wheels or not!... bondo is drying on the tank and now all thats left is to install the wire harness... build a battery box... weld new supports to seat and build a fiberglass seat pan... sew a seat cushion and front brake lever... hope to be riding it next week!... did I miss anything?
 

Attachments

  • 8-1-12 001.jpg
    8-1-12 001.jpg
    264.5 KB · Views: 456
  • 8-1-12 002.jpg
    8-1-12 002.jpg
    256.7 KB · Views: 501
  • 8-1-12 003.jpg
    8-1-12 003.jpg
    285.1 KB · Views: 420
So I have finished the seat base and reinforced the job with cut offs from a doner frame. I also welded the rear brake light switch mount and added a front fender from a 750 maxim to the rear of my bike... and painted the KZ440 tank.. guess you could say I own a YAMAKAWAZUKIONDA!.. Feel a Johny Cash song comin on!.. Still need a complete headlight assembly.. throttle cable...battery and finish the seat!! I want to be riding by the next holiday weekend!
 

Attachments

  • 8-8-12 005.jpg
    8-8-12 005.jpg
    247.3 KB · Views: 496
  • 8-8-12 004.jpg
    8-8-12 004.jpg
    291.5 KB · Views: 450
  • 8-8-12 003.jpg
    8-8-12 003.jpg
    288.7 KB · Views: 468
  • 8-8-12 002.jpg
    8-8-12 002.jpg
    279.2 KB · Views: 458
  • 8-8-12 001.jpg
    8-8-12 001.jpg
    208.7 KB · Views: 446
Well... how about this look.. gives it an early brit bike look. Not really sure about the belt holding down the gas tank... but love the saddle bags!
 

Attachments

  • 8-9-12 001.jpg
    8-9-12 001.jpg
    303.7 KB · Views: 476
So I have been asked to show some images of how I got to where I am with this Frankenstein!.. so first one is front of tank to frame.. second is close call with the pet-cock...third is monoshock mount up frame with tank lifted about 2 inches... four and five are seat framing.. all of the add on pieces I cut from the doner 80 xs400 frame.. don't kill me!.. it was bent before I got my meat-hooks on it!.. six is the left over corpse of the xs400(taps playing in the back ground)... Final paint should happen this week as well as building the fiberglass seat pan.
Any more questions?
 

Attachments

  • 8-12-12 007.jpg
    8-12-12 007.jpg
    313.2 KB · Views: 396
  • 8-12-12 006.jpg
    8-12-12 006.jpg
    305.1 KB · Views: 360
  • 8-12-12 004.jpg
    8-12-12 004.jpg
    307 KB · Views: 377
  • 8-12-12 003.jpg
    8-12-12 003.jpg
    197.5 KB · Views: 381
  • 8-12-12 002.jpg
    8-12-12 002.jpg
    129.2 KB · Views: 381
  • 8-12-12 001.jpg
    8-12-12 001.jpg
    137.6 KB · Views: 362
Well today was a messy day to say the least... Fiber glass!...but got it done!... The wife is busy sewing the seat cover... hope to be done with all that stuff tomorrow. Ordered throttle cable, turn signals, grips and air filters today as well. The saga continues!
 

Attachments

  • 8-18-12 001.jpg
    8-18-12 001.jpg
    268.6 KB · Views: 375
  • 8-18-12 002.jpg
    8-18-12 002.jpg
    176.2 KB · Views: 346
Looking good man. This is one of the only cafe Maxims I have seen. I have the same bike and a few questions. Are the '80 model xs 400 forks shorter or taller than the maxim units? Any reason you switched to those units? Also, did you have to make any modifications to make the '80 xs400 wheels fit the rear subframe?
 
Well... hope I have answers. First I used the xs forks because they are lower.. by almost 2 inches!.. also I wanted the spoke look. The rear fit close.. but I had to add some spacers to get it right. We finished the seat today! here are pics. I twas really hard to get the stance right. The front "wants" to be the highest point of the bike!..would make for a good bobber but you have the whole monoshock thing to deal with... so I raised the back and dropped the front. We will see how it rides in probably a week or so if all goes well.. for today Im going to finish the battery box and wiring.. wish me luck!
 

Attachments

  • 8-19-12 002.jpg
    8-19-12 002.jpg
    308.7 KB · Views: 452
  • 8-19-12 003.jpg
    8-19-12 003.jpg
    308.4 KB · Views: 450
Good luck man, where are you putting the battery box? Please keep us updated on how it rides. Did you raise the rear with just the preload adjustments? Thanks for the answers on the previous q's, its much appreciated.
 
So... no picks today-- but coming soon! I ordered "European superbike handlebars from JC Whitney yesterday and the EMGO H4 headlight showed up today. Mounted up without much hassle and I like how it looks. I will post pics when I get more parts to play with... and I haven't put in a 13 hour day at work! I really need to get going on that gas tank too!.. More BONDO!!!!.. Oooo and as to the rear height.. yes! so far that's all I have done. I found a monoshock off a Yamaha dirt bike at a local bike wreckers.. its all the same for mounting but 2 inches longer with a much beefier spring! Workin on getting them down to a more realistic price or trying to find part numbers and see what it came off of!! and where can I get a shorter front brake cable???... this things pissin me off!
 
OK.. all finished mechanically!!! and everything works with the exception of high beam headlight!... not bad! So all I have to finish is a few finish weld jobs and paint. Still hope to make the deadline of next weekend! Enjoy the picks.
 

Attachments

  • 8-26-12 001.jpg
    8-26-12 001.jpg
    305.5 KB · Views: 422
  • 8-26-12 002.jpg
    8-26-12 002.jpg
    280.2 KB · Views: 383
  • 8-26-12 003.jpg
    8-26-12 003.jpg
    304.3 KB · Views: 373
ITS ALIVE!!!! After its 22 year slumber it started without much fuss at all...Idles perfect at just under 1000 RPM... then you give the throttle a twist and instantaneously it dies... with the choke on and revving 3000RPM it dies if you even breath on the throttle!.. guess I git to take some carbs apart next!.. what an adventure this is gonna be. At least the tank came out nice. Any ideas as what to look out for as far as buy this gasket set and ignore that one?.. help is always accepted!
 

Attachments

  • 9-6-12 007.jpg
    9-6-12 007.jpg
    300.4 KB · Views: 440
  • 9-6-12 004.jpg
    9-6-12 004.jpg
    243.1 KB · Views: 390
  • 9-6-12 003.jpg
    9-6-12 003.jpg
    263 KB · Views: 406
Nicely done, sir!

Good luck with the carbs. Given all the info on the site, just post questions as you have them. You may not need to replace anything... just clean clean clean (make sure you're only using brake cleaner on the metal parts, of course - nothing on the rubber, unless you're itching for a reason to shop for new rubber parts.)
 
Well... Ive had the carbs apart.. they actually looked pretty clean... bottom of right side carb had a little bit of varnish in the bottom of the bowl, but nothing I would contribute to this problem. So it starts and idles perfect but so much as breath on the throttle and it dies instantly!.. if I partially block the crescent vacuum ports on either carb I can get the rpm to come up. If I lift the slides at idle nothing happens. Am I missing something? I saw a post about another xs400 having similar symptoms and he adjusted his timing and end of problem... I don't believe that my twin cam is adjustable however... let alone I don't know which cover to remove! Almost time for professional intervention!
 
Woo_Hoooo! We have lift off!...well sort of. Carbs are working great!.. I used a trick I learned about 25 years ago from my auto shop teacher..(you younger folks wouldn't know bout that).. while revving motor slightly if you cover the mouth of the carb with your hand or "something less flammable" that can momentarily increase vacuum it will suck any debris right through the carb..to a point. There is a limit to how much of this "stuff" you can clear out...BUT now that I have power.. any time I put it in gear I loose spark!..ARRrrGGgg!..will I ever get to ride this thing before the rains come???.. so in this video you see at the end the clutch doesn't drag.. I can spin the wheel with nothing but my hand.. is there a switch in the gear box that I hooked up backward somehow?
 
Back
Top