Dutch '78 cafe build

bossink

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Brummen - The Netherlands
Hi all, I just got my first project bike, a '78 XS400. I bought it for only € 100,- so I didn't have any high expectations. The bike wasn't running and I just had to believe that the previous owner put the bike away with a functional engine.

My plan is to build a cafe racer style bike and learning something about bikes whilst completing the project. I've been riding for about 5 years now but have no real experience in maintaining or modifying a motorcycle. I think I do have some technical insights, and got some good tools (compressor, airlift) so I can only blame myself if things don't work out! :thumbsup:

So,what did I buy?

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This is how the motor was found, partly disassembled but with all parts complete (I hope)

I've just spent one night cleaning only the front chainwheel compartment.....one big clogged black mess! Hard to believe the thing could actually roll!




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Whilst sorting out the crates of parts I found these two beauties:

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Well...What do you think, will this get me a functional bike?

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Meanwhile I've taken out the rear wheel and saw if the electrical parts where complete. I think I'm almost complete but not sure yet. I am sure that I won't need all the electrics because I will leave the turn signals of the bike. Maybe go with a battery less setup?

I've also tried to fit the carburators (tight fit when the intake rubber is cold!) but they are in no way complete. I seem to miss the mounting plates, the idle screw, some parts to make the choke work... *getting the shopping list updated*

I've decided to strip the bike almost bare, but leave the engine in the frame for now. So, worked on getting the front forks out and the handlebar off.

(got some issues with the airlift....)

That's it for now, will keep this thread updated!

Please let me know your thoughts!
 
Looks like you've got the basis of a nice bike there. I really like the colour scheme.

I remember being your age and having the energy to work as fast as you do in your videos.:D

Looking forward to seeing your progress.
 
Thanks for your comments Lyle! Not sure what to do with the color yet. The previous owner spray painted the side black without disassembling anything so I will probably take of most of the black parts and prep them for painting. I also like the blue scheme.... Black and blue should make a nice result I think.
 
Welcome! :)
You snatched that bike from right under my nose hehe
Wanted it for spare parts and the engine as well :)

Good luck
 
Update:
Got the fork legs cleaned and polished.

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Got most of the dirt of with various brushes, brake cleaner, degreaser and rust remover.
As you can see, this dirt has been sitting here for some time now...

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I just used a steel brush on a battery powered screwdriver to get rid of most of the corroded and damaged top layer.
Then, I took some steel wool and a bit of wet sandpaper and got my hands dirty.


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I grabbed some Coca Cola in stead of water because of its rust dissolving capabilities. (and it was just next to me in my mancave-frig :) )

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After that, I used S100 and a polish disc to buff up the fork legs.


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I'm pretty happy with the result! Looking great if you compare them to their previous state imho. And, let's face it; it's a bike from '78...it needs some imperfections :thumbsup:

I'm going to look for a table top grinder to fix the polishing discs to. The battery powered drill works, but you'll drain the battery pretty fast and it's a hassle to get it in a vice. And I'm sure there's more polishing to be done!

See ya!
 
Well well.... it's been too long....

I'm going to revive my project after too long doing nothing. In the meantime I've put my XS in all 4 corners of the garage to make room for the other projects. This winter is XS400 time!

Looking forward to share this revived project with you all!
 
Nice to see there a some fellow Dutchies out here! All tough we are working on completely different models they're all xs400's in the end right. Very curious on what all the outcomes will be!
 
Update:
  • Created a bit of extra workspace with some power outlets on the wall and overhead
  • Installed a Raspberry PI to have immediate access to the forums :thumbsup:
  • Pulled off the tank (which has two small holes) for a colleague to repair (thank you!)
  • Ordered a cordless Dremel multitool
 
Looks like you're making some good progress again. I look forward to watching you with your project. I have stated my own a few months back but my schedule and finds have caused it to stall out. I have new fiberglass fairings due in next week that should get me moving again on my project. Your workspace looks nice. I'd like to get the internet and some tunes in my space that aren't dependent on my phone. I'll keep an eye on your build to help keep myself motivated. If you're interested in my build or if it helps you stay motivated you can check it out it's called XSGP4 build. Have a good weekend
 
Still didn't get started with the actual bike, as my workspace had still some problems.
- The initial wood burner stove was leaking where the pipe went through the roof...had to got that fixed first
- Got my tank back from the welder...it's rusty and a bit dented..but I like the look and fuel will now stay in the tank in stead of dripping down the side of it. I started to get rid the final bits of original blue paint and sanding the tank to the bare metal. will get the photo's up here when I get round to it.
 
I know what you mean. I've been held back by my own problems recently. But I finally made some progress on my project as well.

I look forward to the pictures when you get them up.
 
I know what you mean. I've been held back by my own problems recently. But I finally made some progress on my project as well.

I look forward to the pictures when you get them up.
Thanks for getting some life back into this thread :)

I'm satisfied with the progress so far; the tank looks quite OK like this all sanded blank. My 2nd son was born last week so I'm a little tied up at the baby workbench ;). Although the newborn takes up time, he's also inspiring to give this project some direction. I'm thinking to get the names of my 2 sons on the bike....something to think about.
 
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