budget bike project

jmovt

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Hello All,

first post. Picked up a xs400 for $200, not running, but had heard it run a few years ago. Came with a spare (junk) engine and boxes of parts. I'm not new to bikes, but haven't had a dedicated street bike. I've owned a few dual sports and dirt bikes over the years...random stuff; sp250, ts185, dr350, tl125, etc...a few old bikes that have all been fun. I prefer the older stuff, or can afford it, one or the other. Still have the tl for a woods bike, it's as reliable as a hammer and is real fun on the trails around here. Maybe not as fun as some more modern bikes, but 6hp can still make a guy smile after a day of trail riding without breaking anything

The goal for the project is to just have a decent running reliable bike, built with very little money. I'm not sure what style it fits, but we'll see. I like trackers, but this will transform over a long time likely. Just want to get it together this summer and start from there.

started like this:


I got it home and started making a list of the issues, and parts needed. It's rough, but savable. Had compression and I got all the lights working, etc...so started messing with it. Took the carbs apart and while working on those I got into other things as well.

cut the rear portion of the frame off, since seems like the thing to do. Then took the stock fender and shorted it significantly


Welded up some small tabs to plug the cut frame tubes and hold $8 turns


and cut the factory seat all up and wasn't excited about it in the end, so started to work on a new seat pan now. Using some 1/2" square tubing to start


I got it running too. Carbs still need work, just did a quick job to make sure this thing was going to be worth the effort. Seems healthy enough, so time to get it ride worthy. Plan is to focus on all the safety and reliability thing, then make it my own on the cheap. This forum has a lot of good stuff on it, happy to find it and see some bikes for inspiration and pick the brains of those with a whole lot more knowledge than I have about these bikes
 
Wow, nice work getting it running so quickly! I was expecting the usual habub one goes through with these bikes. A few days of "what the..." and "still isn't..." seems to be the standard around here given the nature of the bikes, but you've got the golden ticket it would seem ;)

I like your plan of attack--safety and rideability first, customization second. That's pretty much where I am at too. I always get excited when a builder is a welder cuz things go so quickly! And I can't weld so I have to live the dream vicariously. Oh well, good luck :)
 
hehe, well I had 3 or 4 late nights trying to get it to fire ;) wiring and needing some help, and it starts so much easier with filters on it of course
Carbs still need work. One cylinder misses occassionally, and it really only likes to rev with the choke on half way or so...will take some time to pull them apart and try again with new parts and stuff, just wanted to make sure I wasn't working with a junk engine.

I say safety and reliability first, but my first post is me cutting it up, ironic. Anyway, yes, that's the plan. Working on the brake system now. Got the rear working well, but the front master is junk. also pulled the throttle assembly apart and may need another. The switches are badly corroded and the headlight switch and kill switch aren't reliable.

Anyone know of a good source for a master cylinder? Or how about those inexpensive ebay masters, worth a try or just a waste of $30? I don't want to rebuild what I have, it was full of water and don't want to deal with it. Wouldn't mind an aftermarket at all, just would like to hear what others have used..
 
Welcome to the forum. If you are going to use the stock air filters use the covers for them. The bike will run better. A good clean and rebuilt carbs are a must for these bikes. Syncing them with a manometer also. There are a few thread on getting started on a bike that has set a while. Just use the search function.
 
Thanks for the welcome. looking forward to digging around here

I don't have the stock covers. I'll either make something or switch to Uni filters if I must. I'd imagine with proper jetting either would be fine.

I know how to search, thanks. I've searched for many nights on this site before even registering. There seem to be a lot of mixed opinions about filters on here.

I will synch the carbs after I give them another cleaning. The prelim cleaning was just to make sure the thing would run and wasn't making any bad noises ;)

I'm still looking at master cylinders. Found a few replacements that could work and read some mixed reviews on here about some of the cheap ones.

No pics today, but I sorted the headlight wiring and got the headlight working. The switch is real bad, but got it to turn on anyway. Cleaned it all up and powdercoated the housing too. Now reconditioning the throttle tube and all the internals of the switches, and installing new cables.
 
Got the brakes working. Installed a new master cylinder and it works fine but the caliper is sticky. Might need a rebuild. Actually rode it down the road quick to verify clutch and gears are good, and all seems fine. Still going to clean the carbs again. Making progress on my seat too.com
 

Got brakes all sorted. Went for a few mile rip to diagnose carbs, but running better and stronger
 
Slowly getting closer.
Fixing little things and cleaning, still a lot to do


Got new tires today. Dual sport tires as I'll be doing a lot of dirt road riding. Are folks drilling the wheels and running tubes when using tube type tires? That's my plan but can't seem to find any threads on here.. and mixed opinions elsewhere. Obviously new tires not on in the pics, just barely spooned the front off.
 

Spooned the front on. Using tubes in them as they are tube type tires. Rear will be a trail wing I got from my brother
 
Thanks, yes its a shinko 244. Its a 3.5" which i was worried about fitting but i can still get the fender on so all good. I went for a quick rip down some dirt roads by my house and like the tire so far. I have a tw40 to put on the rear next
 


slowly getting there. will make a better seat cover and clean up the pipes or change them, and some more wiring to sort, but it's a running/riding pile o' parts now.
 
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