Hello... new project

wallster

XS400 Enthusiast
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Buffalo NY
Hello everyone, thanks for posting all your knowledge for me to soak up. I've been working on motorcycles for about ten years. About five years ago I started a website to share my projects called Wally's Speed Shop (please feel free to take a look around). Two years ago I built an XS650 bobber which introduced me to the Yamaha XS line of bikes (which was pretty cool since I've owned several old triumph's and these bikes are very similar in their set up, but way less expensive to build, plus being a wet sump engine there's no reason for having to plumb in an oil tank). A few weeks ago I spotted a 1977 XS400 on my local craigslist with only 18K miles, but she was in rough shape. The bike had bent front forks and had been neglected but was intact and workable, the owner said it ran but the fuse box was toasted and it had been sitting for a year or two in a barn so I bought it anyway hoping it really did run (I figured I could use the parts for something else since I only paid $300.) I made a fuse box from some old parts and after cleaning the carbs and the points, I got her to fire up.
I've spent that past two weeks working on transforming it into a cafe racer. Even though I have a few months worth of work to finish it up, here are a few pics just to give you an idea of the direction I'm going in. Here's a pic of the bike after I washed it (and before I dismantled it), and a few of it's present condition. I'm documenting the whole build so I'll post it once I'm almost done.
Have fun :),

Wally

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Here's my progress. I got a little side tracked with another project ('92 GSX600 Katana) but that's pretty much done now so I'm back to the XS400 Cafe Racer project. I still need to finish prepping the tins for paint and then work on getting the motor ready to install. The frame was cut, welded, and painted. I installed the new forks (the old ones were bent) and I cleaned and painted the wheels (and they got new rubber mounted to them.)
That's all I have for now, enjoy.

Wally

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Reminds me of the hodaka super rat:laugh:
 

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Made a little more progress today. I made up the wiring harness and soldered all the connections up. The bike actually runs now (kickstart only) so i just have to wire the lights and horn (felt great to hear her fire up and run). The tank and seat section are still at my friends shop waiting on paint. I made some pretty neat decals for them, can't wait to see it all together. Todays pics:

Wally

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wow that is so awesome seeing all the progress you've made. I like your idea of having the little electrical box built right under the seat. Might have to steal that idea haha

Feel free, it's all a matter of inspiration (more so than idea theft). I saw this bike (see below) and had to build a facsimile.

Wally

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Almost complete! I finished wiring the kill switch, lights (on-off) switch, brake light switches, hi-lo beam switch (and indicator lamp), neutral indicator lamp, and I mounted and wired the horn, the electrical is done! I'm still waiting for the gas tank and the tail section to get painted and I still need the chain, front brake (I bought a used one on ebay, should be here tomorow), bolt on the bar-end mirrors, and attach the clutch cable. After all that I'm sure something else will need attention but were making progress. Pics below.

Wally

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Everything is completed on the '77 cafe Racer except I'm still waiting for the painted tins and the foot shifter. Here are the latest pics.

Wally

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Finally got the painted tins back and the bike is complete. I'll wait a few days to fuel up the tank (give the paint a chance to settle down) and I'll get it tuned in. Here are some pics of the completed project.

Wally

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more pics here
 
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