New cafe build

steeze

steeze

XS400 Enthusiast
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Oak Harbor, WA
Hey guys just wanted to introduce myself and my bike a bit....

Im 25, in the Navy, VAQ133 stationed in Whidbey Island WA. I've been wanting to build a cafe for a very long time but between finding the right bike, and the deployment I just returned from, it's been a while. Anyways im back for a few months at least, and finally found the right bike.

1978 XS400 11,333 miles in excellent condition. Zero rust on the frame.. very little pitting on the chrome. The tank and fenders are dent-free and just about scratch free as well. The bike has never been dropped, looks to be all original. The seat is free of tears, all the electrical is there and untouched, and most importantly a clear title in my name. The guy I bought it from rode it last in 2010... he inherited it and took pretty good care of it.







I should also mention this is my first bike... I've ridden dirt bikes most my life and use to romp around on an 06 YZ250F. I've never owned a bike like this nor have I ever worked on anything like this. I do however have tools, a garage, and im pretty damn good with a grinder and welder. I have a lot of experience in metal fab, body work and fiberglass. I have very little knowledge when it comes to motorcycle mechanics but I can figure it out.

Anyways thanks for having me... first things first. I need a new battery...
 
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That is a good specimen; much cleaner than mine was to start. You'll save a lot of money not having to replace things like the fork tubes.

Overall the bike is quite easy to work on and requires very few special tools.

I'd say take the MSF course, but I thought a similar course was required for all military personnel these days.

Keep us posted with your progress.
 
welcome to the site, the bike is on great shape.
don't throw anything away, there's always someone on here who can make use of any spares.
 
Hey Steeze I'm south of you in Vancouver WA working on an almost identical bike, if you need parts etc shoot me a PM

Mark
 
Sure thing Mark.. i'll keep you in mind

Im going to try and get all the fluids changed out... gotta get a new battery just haven't really decided what kind I want to get yet. Also want to clean the carbs...

I did however pull the chrome accessories and battery box with the help of my daughter



 
aye, train her up to do the fiddly stuff like valve gaps and mix screws on the carb.

just don't turn your back or "things" may end up somewhere else :D
 
Got my 4year old to polish the bike:laugh: You have to start them young next thing it do is get him to start cleaning the house:laugh:
 
Had a pretty productive day...

Before I did anything cosmetic I wanted to get the bike running and get it running well. I changed the oil, cleaned the screen, and replaced the filter. I put in new spark plugs, got a brand new AGM battery, drained the tank and filled it with fresh gas, tore down then carbs and cleaned.

Bike starts first shot and runs like new... im pumped.

I pulled the crash bar and the rear grab bar... I pulled that battery box.. right now Im using the stock air filters and a temp battery mount. Eventually I'll throw some pods on and relocate the battery. Im not exactly sure what I want to do with it yet, so I started with what I knew. I absolutely want the engine black so I pulled it out, spent several hours cleaning, sprayed it with gloss engine enamel, and put it back together.





 
Im going with Black and white... white tank and fenders, black frame and engine, black wheels, black seat... etc...

Im going to fab a fiberglass seat and tail, put knee dents in a tank, get some new lights.. relocate and remove some things... should be a good build. This is my first one so nothing crazy planned at the moment. I still don't know exactly how I want to approach the seat and subframe.
 
steeze said:
Im going with Black and white... white tank and fenders, black frame and engine, black wheels, black seat... etc...

Im going to fab a fiberglass seat and tail, put knee dents in a tank, get some new lights.. relocate and remove some things... should be a good build. This is my first one so nothing crazy planned at the moment. I still don't know exactly how I want to approach the seat and subframe.
Click to expand...

Looking great. It's amazing how much good a little paint cam make!
 
Im having trouble searching for the exact answer and don't want to start a thread over it...

I want to order clip ons and im not sure if 33mm is the right size... I think it's 33mm but I want to make sure before I buy them. Anyone know for sure???

Thanks

Oh and wanted to get your opinions on the exhaust... black is so common.. almost too common. Im thinking of spraying them white... I've found VHT exhaust paint in white. What do you guys think of white exhausts?
 
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steeze said:
Im having trouble searching for the exact answer and don't want to start a thread over it...

I want to order clip ons and im not sure if 33mm is the right size... I think it's 33mm but I want to make sure before I buy them. Anyone know for sure???

Thanks

Oh and wanted to get your opinions on the exhaust... black is so common.. almost too common. Im thinking of spraying them white... I've found VHT exhaust paint in white. What do you guys think of white exhausts?
Click to expand...

Just measured my fork and the tubes are 33mm.
 
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Arclight88 said:
Just measure my fork and the tubes are 33mm.
Click to expand...

I think those would look cool. Check out these stunning white ceramic coated pipes!

http://www.subaru4you.co.uk/exhaust/exhausts.shtml

With VHT, I would not be too concerned about possible color fade or discoloration. Opinions varry, but keeping them clean will be made easier if it is a high gloss finish, regardless of color choice.
 

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Thanks Arclight.. I did end up measuring my fork... I couldn't find a ruler with mm so I borrowed one from my neighbor.

I think your right about the finish and discoloration... that was my concern but I think or at least I hope it'll stay white and wont be an issue. I'll definitely have to keep it clean but that's not an issue.
 
Got a little bit more done today... ordered some pods, got a helmet, painted the front fender white... I thought long and hard about modifying/cutting the fender but I decided that it looked just fine the way it is. I may still cut it up one day but for now it's fine...

I also painted the forks black... the seals were still good, so i'll run it a little longer before I change them out. I painted the rear shocks white... I thought about doing the spring black but decided to just spray the whole thing white... it's growing on me.

Im going to go out and clean and paint the front wheel... also going to tear down and clean the caliper. Brake pads are still good so just a good cleaning.

I'll post some pics later when I get the front end back together...
 
Painted the exhaust black... the white wasn't going to work and didn't look as good as I hoped. Here's a few pics of where Im at so far...







I still don't know how I want to do the seat and tail... I have the flower foam and im ready to start making a mold. I even have all the fiberglass and body filler and all the shit I need I just don't know how I want to approach it. I know I want to cut some of the sub-frame off... Im just unsure of the design.
 

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