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Going to contribute to this thread with a ledger sized and coloured 1977 XS400D Wiring Diagram.

I'm no welder but I think popping the MIG to "high" and upping the feed speed would give you a nicer seam without punching through the sheet metal. Well done on the fabrication though! Project is looking nice. What happened to the frame on the left side of that last photo? The 2k holding out...

The "bridge" between the frame segments (just infront of the shock mounts) is what provides rigidity for the frame at that location. I'm pretty sure the loss of the fender won't compromise the strength of the frame. Coincidentally, I did the same thing (although I removed the shock mounts...

Got four plated steel M8 bolts for $1.00 from my local NAPA. Those guys are the best! Thanks everyone for the recommendations; I'll post a photo once the exhaust is back on my bike!

If you find the piece I imagine you could repair it by brazing it back on, though I have no experience with this and can't confirm the validity of that suggestion. However, the cast aluminum is pretty porous and brazing uses capillary action to distribute the filler, so with an aluminum...

True that. Besides, it's cheap to buy M8's and modify them... probably $0.80/bolt then some modification with a hacksaw and vice grips. Now, while we're talking about damaging the head, what antisieze are you guys using? I've got some Permatex Copper but the galvanic potential is quite high...

Goodness, now there's a concept! Thanks for the tip Jeff!

They're M8x1.5 right? I'll go take a look at some local stores on Monday when they open up again.

Let sleeping dogs lie. If the engine works then I would keep it how it is! Once you go in you can't come back out unless you spend money on the parts (new gaskets, seals, etc.) that will very likely break. Otherwise just keep at er, things are looking good so far! Except for the taco cable. Lol.

I hate to start a thread for this question but where the hell are y'all sourcing your exhaust studs from? PartsnMore has them for $12USD, then $20USD shipping(!?) so I'd rather find an alternative. I was going to make my own from stainless but that makes a pretty serious galvanic potential...

As far as I can tell you should be fine. Current can kill a circuit (and lots of other things) but so long as you don't exceed the voltages (which isn't possible) you'll be okay. It can output 1.5A and it won't be able to "force" 3.0. It seems to have a current sensing capability so it may limit...

Fair enough mate. My ideal bike would be the KLR 650 with my old '05 GSXR600 engine in it. I just loved riding that tractor but wish it could chooch a little harder.

Looks like a cool ride! People knock those couch cushions but damn are they comfy. Think you'll endeavour to create this hybrid?

That's a nice solution to replacing the chain guard. Did you weld plate together or use a channel?

Love the diamond sheet!

As someone who began in the same place you are I'll echo a few things here: 1) Download all of the manuals you can for your bike; pick up a Haynes or Clymer because they have step-by-step rebuild instructions. 2) DO NOT take anything apart without ensuring you have the proper understanding...

Honestly 0% chance of it being a direct swap. Sure they're both Yamaha but that means nothing for bike fit. If you buy the motor you can probably make new mounting hardware but you'll need so much more to make it work (proper carbs, so new carb holders, proper airbox, etc. etc.) I wouldn't...

I edited the first post but want to bump: I'm looking for a '77 front caliper, a front master cylinder, and a rear brake rotor. If you have any of these components I would love to hear from you before I'm forced to pay shipping out the bunghole from ebay!

Are you in the Canadian Sussex or the UK one?

PO said his friend came and stole the entire rear brake assembly from his bike before he sold it to me. I'd like to replace it with stock, so please shoot me an offer if you have the parts. I'm rockin' the mag wheels so I would like to avoid drums. Thanks! EDIT: Turns out I don't need a rear...