80 XS400 Build

[Mawx]

New Member 80 Heritage XS400SG Cafe Racer project

Hi all,

My cousin started building cafe racer's about 1 year ago. I asked him to build me one. I mocked up some designs in photoshop. The bikes about 2 weeks from complete. The bike was started on April 1st 2012.

Here is a time lapse vid of the teardown and begining fab first 3 days of the build:

The only catch throughout the build was the gas cap. The tank is a XS360 tank but it had no cap. I found most people online in the states were selling XS650 caps claming they were compatible with XS360's which is not true. With a few days of research I figured out the XS360 was re-released as the RX100 in Japan. We ordered a RX100 gas cap from Bangledesh and it was the right cap. So FYI if you ever need a XS360 cap.

I'll post the finals at the end of the month! This is my first bike I'm so stoked!
Hope you like it my cousin Caleb is amazing IMO he has hit the mark with this one.


Added new and updated images after some cleanup.
Begin

With 360 Tank on

Should have seen my face on this one.

frame

Frame with 360 and Clubmans

Engine Pre-Cleanup

Springs after cleanup / Paint Gloss Black

Cousin Fab

After Fabrication and bodywork

 

[PT_247]

cool, keep updating the thread with pics

 

[drewpy]

welcome to the forum.

good info on the petrol cap

 

[Mawx]

More Fixed Picks
Painted





Lights



Speedo

 

[Mawx]

To do list left:
Ignition
Headlight
Taillight
Seat
Vinyl
Grips

 

[xschris]

Very nice!

 

[Mawx]

Here are some picks from throughout the build:

Frame after tear down, rear section cut, cleaned, sanded, painted with engine painted / mounted and front forks back on:
The rear springs we used a cutter / dremil (sorry not the most tool savy yet) to shear off the extra chorme to get a raw spring look.
Mounts we left orginal.


Wheels after cleanup / tapeoff and repaint:
Was going to black them out but the rest of the bike was so dark we wanted some contrast here


Brakes drilled, for looks but does it help with cooling too?


Rearsets, custom made by Caleb, he used the existing frame and added a bolt to attach these, they are also adjustable / angle etc.


Here is the orignal Mockup in photoshop on the bottom with the bike where it was about 3 - 4 weeks ago. I'm truely amazed and how close Caleb got when he looked at this picture one time...


More to come thanks for the comments guys, I hope to pick up another bike by winter so i can start my own tinker project

 

[dO-bOy]

Really good idea using the muffler mount for the rearset!

 

[Mawx]

Yes that is right he did use the muffler mount to do the rear sets. I'm about 5' 8" and it fit me like a glove in that location.

 

[Mawx]

Here is the trailer my dad is building me it'll fit 2 bikes or one centered looks rough now but it'll be amazing when its done.

 

[Mawx]

Moving fixed pictures up in post

 

[xschris]

Where do you get the speedo is it the mikesxs one? Is it the accurate ratio?

 

[Mawx]

Drag Specialties off ebay i believe this is the one.

http://www.ebay.com/itm/4-LITE-LIGH...Parts_Accessories&vxp=mtr&hash=item2eb86bbc50

 

[bentwrench]

What did you use on the engine? That's a luscious colour!

 

[Mawx]

I believe we used Cast Iron I'll check for sure when i pick up the bike. I leave to get it on 5/26/12 it can't get here soon enough!

Got my endorsement Sunday! I'm official? but bikeless haha, and everyone made a point to ride in today so I'm staring at 8 bikes in the parking lot its torture!

My bike is going to look funny small next to all the 800's and 1000's but hrm mine will be 300-350 pounds wet?

 

[Mawx]

To do list for today:
adding petcock, checking for any gas leaks, cross fingers ROOOAARRR!

Trip to color checker, Trip to vinyl guy. Vinyl should match the engine, I'll get the color number from my cousin tonight if he remembers to write it down.

 

[Mawx]

Cousin said bike fired 2 mins after he put gas in the tank! Said the exhaust sounds incredible. As soon as i get a vid i'll post it.

Remaining tasks after Tuesday next week:
Put tank of for the last time, Put logos / decals on, build and attach seat.

DONE!

Engine base coat

Engine Second Color

Original Project bike first day home

Modified Exhaust

Modified Tail cutoff just behind springs then used old handlebars to manufacture the brace

Fabricated Seat / tail

Dad and I working on my trailer last night.

Rock Shield almost done

 

[Mawx]

Decals side profile, cousins business logo and 1927 yamaha logo



Rear, double race scripes. Trying to decide to continue this to front vendor off-centered or leave it black hrrmmmmm.


Trailer my dad is building needs to hit his paint booth and thats about a wrap!


Bike is running flawless, had a small vacum leak but that is fixed. Also had small oil leak around the shifter but that is ussually just a seal.
I have a video but can't post cause its in a weird format.

I pick the bike up this Friday / Saturday and will definately have videos posted of me riding if weather permits!

 

[Mawx]

Shots of the seat finished, cousin rode her today and said this bike is a blast.







Cant wait to ride!

 

[FUBAR]

wicked paint and seat man