My XS400

[SoulMan]

When I saw the left hand controls I thought there has to be something wrong with this. This doesn't look right cuz it look like some cables are cut but I hadn't tried to use them or put everything all back together completely. And then I finally realized it when I was trying to wire it up. Controls on the left are from my extra bike and the controls are from the bike I'm currently working on



I also struggled to get the front turn signal indicators on in the headlight bucket and then I realize it. It's I was trying to do it without taking the front of the headlight off and that it would be much easier if I took the front headlight off to do it. You live and learn I guess

 

[SoulMan]

And just a note for myself after the cut. It's about an extra 25 in of wire until the terminals are there and it's about 30 in total if you were going to remake the whole thing

 

[SoulMan]

I still had to get it started with a punch but after making a little bit of space between the bearing and the bearing spacer this made quick work of getting the bearing out

 

[CaptChrome]

Great progress!

I was planning on installing these all balls bearings I purchased but now I am on the fence and considering trying to use better bearings but wonder if I should just install them and if/when they start to act up just install the oem bearings. Thoughts?

I installed the All Balls Racing bearings and they have been fine for 7k+ miles. If I had a nice set of SKF or Timkin bearings laying around, I would have used them, but the All Balls seem fit for purpose. My opinion is just install them and save your money and time for something else.

 

[SoulMan]

This morning I swapped the stator from the 2nd bike to my bike because the wires coming out of it were better and I'm it was able to route them and everything where they need to go. So that was great. Hopefully that statter works. I have no idea hasn't really tested any either. The staters for that matter just because I've gotten it started but I haven't ridden it for any long distance but that is a messy job getting the wires routed where they need to go

Sad thing. Is the wiring coming out of the stator wasn't like this when I bought it. I must have cut it open for some reason. I don't know why

 

[SoulMan]

And on that note, do you happen to have any suggestions for like a new protective wrapping? I don't even know what it's called to put around the wires and stuff to kind of rebuild. What should be there on the other stater?

 

[SoulMan]

So. Installing the rear bearings. The non chain side went inike butter. I heated the hub and had the bearing frozen. Went to do the chain side bearing and no such luck. I had to hammer it. And now it just doesn't want to go in any further. There is a gap between the bearing and the spacer but yet I cannot get it to go in further

 

[SoulMan]

I'm screwed... This is the axle bolt in the center of this bearing Iit sn't the right bearing. Unfortunately I didn't compare the bearing before installing.... This isn't going to come out easily

 

[SoulMan]

Well I guess it's the right outer diameter just not the right inner diameter. I was able to get it out just fine with the blind bearing puller

 

[SoulMan]

Well I didn't realize that there was a bushing of some sort in the old bearing. shit

 

[SoulMan]

Can I reuse that bushing after I make sure to clean off any kind of burr or whatever on that or is it meant to be a consumable?

 

[CaptChrome]

Can I reuse that bushing after I make sure to clean off any kind of burr or whatever on that or is it meant to be a consumable?

That looks like the wheel collar - clean it, remove any burrs and reuse it. It is not a consumable part.

 

[SoulMan]

That looks like the wheel collar - clean it, remove any burrs and reuse it. It is not a consumable part.

Yeah I saw online that said that was a part that's hard to find. So I was planning on finding my round file and just just clearing off some of the burrs that make it so it can't slide onto the axle and then using it. That's my plan at least

 

[SoulMan]

I'm a little bit lost in the sauce trying to connect the front end electrical. Obviously some of the connections are well ..... obvious but some of these bullet connections I'm not sure what plugs into what exactly.. I finally found one color match from a male to female bullet

 

[SoulMan]

Well I looked at the service manual and found the xs400g in there. I think I have the wiring sorted out one of the turn signal indicators I got from somebody else and he uses a non-standard plug so it doesn't fit the connection. But I have a kit from Japan coming so I'll be able to fix it at that time

 

[SoulMan]

Today I installed the carbs, the h-pipe, the air filters and I fixed that little bushing or whatever for the axle. I also worked on the electrical and I believe I have all the electrical stuff sorted out so getting ready. Once I get that bearing tomorrow probably get it installed Tuesday evening.

After get the bearing installed. I will install the rear wheel, get the battery installed, get it off the floor jack, install the exhaust, change the oil and try to get her started.

 

[SoulMan]

I got a quick question for you Capt. When I first got this bike it kept blowing the main fuse. I thought I tracked it back to the cancel unit but I wonder if everything was wired up correctly before so I was thinking about putting the cancel unit back in and just seeing if the fuses continue to blow, but I can't find actually where it gets installed where the connectors at and where it you know attaches to the frame. Can you give me an idea where that's at?

Oh I filed down that bearing collar to clean up where it got damaged by the blind bearing puller and when I had to hammer it out of the bearing. So it slides onto the axle fine now

 

[SoulMan]

I found the cancel unit. The main reason I couldn't find it before was I must have purchased a different unit and plugged it in near the battery area where it is supposed to be plugged. The previous one was blowing the main fuse. So I should be good to go on the auto cancel.

Anyways I installed the battery today to see if the wiring looked good and when I turned the ignition to the on position my left turn signal turned on solid. So chased electrical demons for a while. Thought there was a short somewhere that was only in the front and not making it back to the rear turns signal so I cut the chocolate wire from the double barrel connection in the front to see if the short was in the main wiring harness. When I did that my neutral and oil indicator lights no longer worked. Turns out the chocolate looking wires are actually darker than the brown looking wires and I had cut the 12v to the instrument cluster. So soldered it back together shrink tubed it and put the left turn signal indicator on the proper chocolate wire and now it is good and no longer on.

I am inching closer to the finish line here.

One additional question I have an open ground spot in the front of the bike with a ring terminal on it. Where on the frame does it connect? The two turn signals are plugged into the double ground wire bullet terminal. My understanding is this other terminal on the front is another frame ground terminal. Thanks!

 

[SoulMan]

Getting there

 

[CaptChrome]

I was thinking about putting the cancel unit back in and just seeing if the fuses continue to blow, but I can't find actually where it gets installed where the connectors at and where it you know attaches to the frame. Can you give me an idea where that's at?

It sounds like you already figured this out, but I will respond just in case that isn't true.

The cancelling unit mounts to a metal tab that is under the frame cross member that the rear end of the fuel tank bolts to. Here is a pretty bad picture of the tab looking up under the frame with the mounting tab circled. The other tab clearly outlined is for the flasher relay.

The plug to connect the relay will be nearby and comes from the main wire loom that runs along the top left-hand frame tube.

One additional question I have an open ground spot in the front of the bike with a ring terminal on it. Where on the frame does it connect? The two turn signals are plugged into the double ground wire bullet terminal. My understanding is this other terminal on the front is another frame ground terminal.

On the '80, '81 and '82 SOHC bikes there are two main grounds. The first is the negative battery lead bolted directly to the engine case. The other is a black wire with a ring terminal that bolts to the frame near the fuse box. There are then four other grounds associated with each turn signal. The front turn signal ground wires are inside the headlight bucket and bolt to threaded end of each signal. Similarly, the rear ones are routed inside the rear fender and also bolt to the end of the turn signal stalk like the front ones.