My XS 400 Cafe Racer Project

Thanks!

That's motivating! Next week i'll post some pics. Currently i'm away from home and unable to do some work so i'm trying to figure out how to rewire my bike... That's tricky.
 
Not much time for work recently, but i managed to made myself new speedo indicator (second one is only printed).
Still thinking about new disc -for now it's paper cut.


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Hi very one!

It's been a while since my last visit here but i i need to share with you my last success - WORKING ENGINE!!!! YES! I've made it!! This feeling after you hearing engine running smooth after one year of work is something incredible :) You knew then that all of this wasn't for nothing.

Ofcourse i need to adjust valves and do a lot of other stuff for example replace my temporary fuel tank (apple juice bottle) with proper tank :D

Anyway, here is the movie from running the bike after whole weekend of fight.

www.youtube.com/embed/UBhv1dD0HdM

Ofcourse after reassembly not everything was going smooth. Whole Saturday i was kicking kick starter like crazy and couldn't figure out why engine refuses to start.:wtf: After some advice to put petrol through spark plug holes it was clear that something with the ignition is wrong - And as it turned out, i adjusted ignition on exhaust stroke...... after changing this bike starts with the third Kick!


Here are pics with the reassembly:

According to drewpy's awesome advices i managed to put together new wiring. And maaan it was tough job to do. It took me about 4 days to complete it, not mentioning time spend on planing and trying to understand wiring diagrams. But... After everything was on bike it worked! Yay!!!

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Painted seat frame

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Carburetors in place with new filters. I would have to figure something out about filter sticking out from the engine. It touches carburetors and i don't like it :D

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Installed rear sets with linkage to the rear drum. It almost works :D

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Thats why you shouldn't work on your bike at 3.30 am ;D

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With temporarly fitted headlamp

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I definitely need to order new front brake hose :D
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Aaaand some detail work:

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And final speedometer (air bubbles disappeared after one day :) )
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Handlebar switches:

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Next update in two weeks! :D
 
Thanks!

I've spend a few hours wire brushing them by hand. After that designed stickers and printed them on transparent adhesive foil. After putting them on control switches i I painted everything with transparent spray paint.


EDIT: if you ask about "buttons" i did not paint them but i used some chemicals from local producer to get them clean and later i used some kind of blank ink for old plastics. It worked quite ok!
 
you rearsets are foldable? Is there enough space for kickstart lever?


Hi!

Unfortunately they are not foldable :) that's one of the drawbacks. Since i designed them by myself i couldn't figure out how to make them foldable :shrug:

Yes there is space for kick start. You can see me starting bike with it in the youtube video link on top of my previous post.
 
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