Hønen & Ræven customs - Ayrton Senna customer build

Hi,
We are a small company from Denmark, 2 guys, a 54 m2 garage and a lot of beer.

This is the first build for our little shop in Denmark, a client wanted us to build a Brat/Cafe bike with a Ayrton Senna theme.

We found a XS400 in Germany and brought it to DK for tear-down and assessment.
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Did at complete stripdown of the engine.
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Ported the engine
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Shaved unnecessary brackets and welded a new rear end (Hoop) with a 20 degree kick
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Painted the engine with VHT Engine paint.
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Next step is getting the last stuff mounted on the frame (rear set, licensplate brackets, passenger footrest, get the frame sandblasted and powder coated, assemble the engine with new timing chain, bearings, seals and gaskets.

The deadline for the bike is February.

#UPDATE 24/11-15#
Got some work done to the seat pan, and tested the rear set mounting.

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Pretty happy with the 100$ rear set that i got of eBay http://www.ebay.com/itm/b-CAFE-RACER-REAR-SETS-IN-BLACK-ALLOY-NEW-FREE-P-P-/262003705701?hash=item3d00a34765:g:9QYAAOSwLVZVzKVY

I´m going to shave quite a bit more of the seat pan when i get some more flapdisc´s 1.5mm stainless takes a toll on my anglegrinder


UPDATE 11/02-16

It´s a new year and we need to get cracking.

We finished all the wiring and the rest of the framework.

The original wiring was filled with rotten wires and backyard fixes, so we needed to start over.
First off we made a box for the LiPo battery, relays and such.
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The client wanted a usb output, and we wanted a clean "dashboard" so his phone becomes the speedo, and the 3 leds are indicator, oil press and neutral.
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Next up is powder coating of the frame, and shipping the tank of the painter.
The deadline is 28/03-16

Got all the engine parts, including the last 6 crankshaft bearings in that tolerance, in the world (I hope) they cost me 300$ including shipping for 6 pcs.

So I assembled the engine and will try to fire it tomorrow
[/URL]

Got a complete stainless bolt kit.
Gives the engine a great look.

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#UPDATE - 7/4-2016#
So the powder coat had to be redone, and ended up taking over 3 weeks, deadline gone

But anyway, now the assembly begins, and hopefully the tank and seat is done before the end of this month.
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Its not true flat black, a bit more glossy that usual, im really happy with the result.
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#UPDATE 06/09-16#

OP here, i am happy to se more positive people in here than negative!

The build is done...

I just finished up the last few details tonight, getting parts for this thing has been a bi***
You are only getting pics from a couple of weeks ago when the bike was missing a few details (Filters, cleanup of wires ect.)
Ill get back to you when i get some pro pictures down.

Thanks for your support!!!





Please dont hesitate if you have any questions.

nice, looking forward to more.

welcome to the site

Looking good and welcome to the forum.

Curious to see how the Senna theme works out.

Update 24/11-15

Update 11/02-16

no message?

drewpy said:

no message?

Click to expand...

He updates the first post.

I see
(said the blind man)

Another XS400-builder from Denmark - welcome

The build looks good !

Update in top post.

Update in top post 7/4-2016

$300 for 3 journal bearings? You know you can order them new right? You don't need to have oem. Just give a bearing place the specs you need. Shouldn't be anywhere near $300

Our cranks take six. Was not aware of people making them. There where four sizes avalible when these motors were made. I guess you would have to spec the crank and the case then look up the tolerances to see what you need. Then find a shop that can make them.

xschris said:

Our cranks take six. Was not aware of people making them. There where four sizes avalible when these motors were made. I guess you would have to spec the crank and the case then look up the tolerances to see what you need. Then find a shop that can make them.

Click to expand...

When I say 3 I mean sets, so yes 6.
Anybody that makes crank bearings will make them, as long as you give them the right numbers. Was looking into it when my bottom end was going back together, I got a few quotes but in the end my bearings were fine.
Forgot which place, but they had a nice order sheet PDF with diagrams and you just fill in the blanks and send it in. Think it was one of the big muscle-car crank places, they make custom bearings all day everyday. I bet they have tons of 'blanks' and just machine them to spec.

The sohc xs400 was not a common size for yamaha and was not used on any other yamaha bike. As for car motors I am not sure on there sizes "matching up". I can't imagine them making them for "cheap" . I would like to see the cost. I started collecting all sizes OEM for the last 6 yrs when they stated drying up and prices went up. I have enough to last my xs400 driving life and my sons when he gets them.

UPDATE IN FIRST POST

Looks great!! nice work!!

What Led headlights do you choose?? Easy to wire??

We redid the entire wiring so it was easy to fit to the new system.
But overall i would say its a pretty easy job.

We used this headlight
http://www.ebay.com/itm/Black-Metal...-Cafe-Racer-/191773227661?hash=item2ca6933a8d

Mekai said:

Hi,
We are a small company from Denmark, 2 guys, a 54 m2 garage and a lot of beer.

This is the first build for our little shop in Denmark, a client wanted us to build a Brat/Cafe bike with a Ayrton Senna theme.

We found a XS400 in Germany and brought it to DK for tear-down and assessment.

[/URL]

Did at complete stripdown of the engine.

[/URL]

Ported the engine

[/URL]

Shaved unnecessary brackets and welded a new rear end (Hoop) with a 20 degree kick

[/URL]

[/URL]

Painted the engine with VHT Engine paint.

[/URL]

Next step is getting the last stuff mounted on the frame (rear set, licensplate brackets, passenger footrest, get the frame sandblasted and powder coated, assemble the engine with new timing chain, bearings, seals and gaskets.

The deadline for the bike is February.

#UPDATE 24/11-15#
Got some work done to the seat pan, and tested the rear set mounting.

[/URL]

[/URL]

[/URL]

Pretty happy with the 100$ rear set that i got of eBay http://www.ebay.com/itm/b-CAFE-RACER-REAR-SETS-IN-BLACK-ALLOY-NEW-FREE-P-P-/262003705701?hash=item3d00a34765:g:9QYAAOSwLVZVzKVY

I´m going to shave quite a bit more of the seat pan when i get some more flapdisc´s 1.5mm stainless takes a toll on my anglegrinder


UPDATE 11/02-16

It´s a new year and we need to get cracking.

We finished all the wiring and the rest of the framework.

The original wiring was filled with rotten wires and backyard fixes, so we needed to start over.
First off we made a box for the LiPo battery, relays and such.

[/URL]

The client wanted a usb output, and we wanted a clean "dashboard" so his phone becomes the speedo, and the 3 leds are indicator, oil press and neutral.

[/URL]

[/URL]

[/URL]

Next up is powder coating of the frame, and shipping the tank of the painter.
The deadline is 28/03-16

Got all the engine parts, including the last 6 crankshaft bearings in that tolerance, in the world (I hope) they cost me 300$ including shipping for 6 pcs.

So I assembled the engine and will try to fire it tomorrow

[/URL]

Got a complete stainless bolt kit.
Gives the engine a great look.

[/URL]

[/URL]

[/URL]

#UPDATE - 7/4-2016#
So the powder coat had to be redone, and ended up taking over 3 weeks, deadline gone

But anyway, now the assembly begins, and hopefully the tank and seat is done before the end of this month.

[/URL]

Its not true flat black, a bit more glossy that usual, im really happy with the result.

[/URL]

[/URL]

#UPDATE 06/09-16#

OP here, i am happy to se more positive people in here than negative!

The build is done...

I just finished up the last few details tonight, getting parts for this thing has been a bi***
You are only getting pics from a couple of weeks ago when the bike was missing a few details (Filters, cleanup of wires ect.)
Ill get back to you when i get some pro pictures down.

Thanks for your support!!!

Please dont hesitate if you have any questions.

Click to expand...

Love it.

drewpy said:

I see
(said the blind man)

Click to expand...

...Peeing into the wind, "It's all coming back to me now."

Awesome build! Love the headlight with neutral, oil, and indicator, plus the frame looks EXTREMELY neat and tidy with that elex-box. Out of curiosity, what did you do for the carb intakes? I know your final photos are not the completed bike, so did you stick pods or stacks on there?