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Can't pass up a chance at new rims.

This should help http://www.merrittmotorcyclesalvage.com/yamahaidentification.htm

Somebody put a lot of heart and soul into this build, one of those bikes that inspire. http://www.bikermetric.com/2011/09/reader-rides-drews-yamaha-xs400-street.html :thumbsup:Excellent Work, Drewpy

Do you plan to keep the seat as is, or do something different? That would have a bearing on the total flow of the bike design and maybe a decision on what type shape and size tank you want to make.

Sometimes the problem goes beyond the explainable and you need to call a professional in. Seriously though, as Drewpy said, we're giving as many ideas that we can think of, based on what you're telling us. They may or may not help, but they are worth checking out. Your TCI could be...

In one of his other threads he said he has an '82, the DOHC model, doesn't have kick start or points.

Do you have a multimeter or just a cheap continuity tester? Use that to check kill switch and ignition switch. Check for continuity across the fuse box. Do you have access to a wiring diagram? Here's a link from the forum: When you tried starting, shouldn't need to hold starter button for more...

What have you done ignition wise? Timing, wires and caps, what spark plugs, tested coils?

Did you charge the battery after you topped it (low amp charge, 2 or less)? Do you have a multimeter to check charging system on bike, should be around 13v at idle, to 14 or so at higher RPM.

I don't know how proper this was. One time I was replacing the seals on a Honda. that probably hadn't been replaced since it was new, about 30 years. I couldn't do any of the usual to get them out. Getting frustrated, after a couple days working on it I got extreme. I stuffed wet rags into the...

Have you looked at the color of your plugs? Sure both cylinders are firing? Did an ohms test on you coil? Checked the resistance of spark plug caps? Compression? Valve shims? Timing chain tension adjusted? Enrichment or choke working properly, on when you want, off when not? Lots of possibilities.

Welcome to the forum. There are several different models of XS small twins on this form, most ranging from the 360 to 400 Single Overhead Cams to the '82 and up XS/XJ 400 Double Overhead Cams (I think there are also a couple 250's). Go to the tech section, you'll be able to find more info on...

From the tech section under suspension: http://www.xs400.com/forum/showthread.php?t=4553 Here's a link to lowering XS650 forks. http://www.xs650.com/forum/showthread.php?t=5537 The forks are different, but the principle is the same. Also, the online manual you can download, covers forks...

I checked the parts PDF at Yamaha ( http://www.starmotorcycles.com/partviewer/default.aspx?ls=star ), for the carbs http://www.starmotorcycles.com/partviewer/default.aspx?ls=star#/Yamaha/XS400J_-_1982/CARBURETOR/XS400J_%281982_MOTORCYCLE%29/CARBURETOR_%28XS400J_-_1982%29 and for the DOHC there...

I think you'll need the rubber plugs, I know my carbs, from an '81 have them. Copied this from the carb guide, page 9 of the PDF file Mike's XS has them. http://www.mikesxs.net/products-39.html#products Z1enterprises, sold in a set of 4...

Basic carb guide from the 650 forum, covers BS34, not sure if your bike has that carb, but it would still be worth looking at. http://www.amckayltd.com/carbguide.pdf

It could be done, you would need to swap the charging system to a permanent magnetic. One fellow on the list has successfully done that. http://www.xs400.com/forum/showthread.php?t=4648

If you haven't downloaded the manual here's the link: Go to page 23 of the PDF, that's where the electrical section starts, tells how to test system for charging, test your coils, etc. What Drewpy was referring to was the TCI box, if you have '80 or '81, electronic ignition, not electric start.

How long does it take you to start the bike? If everything is even close to up to snuff, it shouldn't take more than one - three pushes on the starter button. Did you charge your new battery fully before you put it in the bike?

It has been updated, and solved. http://www.xs400.com/forum/showthread.php?t=4648