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New member First Bike First Build

Discussion in 'The Garage' started by XSDunn, Oct 28, 2016.

  1. XSDunn

    XSDunn XS400 Member

    Hey guys my names Alex I bought a '78 xs400 a while back and finally decided to start building her this winter. It's my first bike, I'm hoping to learn as I go and learn a bunch from my fellow forum members!
    Now the bike I bought disassembled as the previous owner who was going to turn it into a cafe racer. The plan is to resurrect the bike into a scrambler/brat. I have already began to strip all unnecessary parts off and clean up the frame, prepping for a rear hoop and electronics tray.

    Parts on order:
    - Rear hoop, diy rear fender, scrambler front fender, carb holder, speedo holder and indicator brackets from Two Hands Motorcycles.
    - Brembo PS13 rear master cylinder (factory is shot)
    - Stainless brake lines
    - Zero Dark 7" LED Jeep Wrangler headlight
    - Gazi Sport Lite shocks
    - XS650 reg/rec from MikesXS
    - LED indicators from BAAK Motorcycles
    - Shock mount plate holder from Gasbox
    - Bates LED taillight
    - Sparck Moto harness
    - MMCC switch blocks
    - Antigravity 4-cell
    - Honda ignition switch
    - Bronze swing-arm bushings
    - Tapered steering bearings
    - Mini speedo from Cognito Moto
    - New coils
    - Pod filters

    Currently have super-bike bars from DCC, Domino throttle, Nissin 14mm front master and a clutch perch + lever from a 08 Kawasaki ZX10R for controls. I'm going to the front fork mods and brake disc drilling mentioned in the XS650 Minton Mods article. Motor will be rebuilt with fresh gaskets and seals, carb rejet, possibly a 2 to 1 exhaust, and electric ignition.

    Thanks again guys!
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    Jeff0133 likes this.
  2. Jeff0133

    Jeff0133 XS400 Junkie Top Contributor

    Welcome, looking forward to your build thread
     
    XSDunn likes this.
  3. XSDunn

    XSDunn XS400 Member

    Made a little more progress as Im waiting for the rear hoop and fenders, the old factory rear master cylinder was shot and I bought a Brembo PS13 to replace it. Made some mounts (hardware is 6mm x 1.00) and turned a new push rod (threads are 8mm x 1.25) out of stainless which is about 3/4" longer than the factory to provide plenty of swingarm clearance. Haven't had the chance to weld it in place yet.
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    What have you guys been running as replacements for the factory brake rotors? Also does anybody on the forum do custom fab? Looking to get a electronics tray made!
     
    Last edited: Nov 17, 2016
  4. XSDunn

    XSDunn XS400 Member

    Got parts from Two Hands Motorcycles the other day! Got to work on the tail, more to come.
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  5. XSDunn

    XSDunn XS400 Member

    More progress! Removed the factory crossmember, and replaced it with .75 x .125 tube. Added mounts for the rear aluminum fender as well. Currently sitting at ride height with the Gazi shocks.
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  6. xschris

    xschris XS400 Guru Top Contributor

    Nice. I am not sure if your aware but them forks are on backwards.
     
    XSDunn likes this.
  7. XSDunn

    XSDunn XS400 Member

    Thanks and yah the whole bike is backwards haha
     
    Last edited: Jan 17, 2017
  8. NewHavenMike

    NewHavenMike 1976 XS360C Top Contributor

    That hoop is exactly the shape I was going to do myself to match the gastank shape and overall squareness of the bike. Ive contaced two hands about shipping..
     
  9. XSDunn

    XSDunn XS400 Member

    Great quality products and they just switched to UPS as a shipping carrier so shipping was fair and fast.
     
  10. OleDoc

    OleDoc FREEBIRDS MC Central NY

    looking good
     
    XSDunn likes this.
  11. XSDunn

    XSDunn XS400 Member

    Thanks!
     
    OleDoc likes this.
  12. OleDoc

    OleDoc FREEBIRDS MC Central NY

    you're welcome
     
  13. Raw Sketch

    Raw Sketch XS400 Member

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  14. NewHavenMike

    NewHavenMike 1976 XS360C Top Contributor

    Did you slug the rear hoop? Is there a place that makes them?
     
  15. XSDunn

    XSDunn XS400 Member

    Yes with 3/4" round stock and Two Hands Motorcycles sells the hoop!
     
  16. 81xs400sfttailbbr

    81xs400sfttailbbr 81xs400sfttailbbr

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    Awesome build...dont mind if a follow the build and take some pointers! im building a 81 xs400 right now
     
    XSDunn likes this.
  17. XSDunn

    XSDunn XS400 Member

    Thanks! Do you have a build thread?
     
  18. 81xs400sfttailbbr

    81xs400sfttailbbr 81xs400sfttailbbr

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    I currently do not but i am going to start one this weekend! Im having alot of trouble rewiring mine..being that i am not good at wiring!
     
  19. XSDunn

    XSDunn XS400 Member

    I'm in the same boat haha I decided to ditch the factory harness and use a DIY kit from Sparck Moto which will hopefully help a little.
     
  20. 81xs400sfttailbbr

    81xs400sfttailbbr 81xs400sfttailbbr

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    Hahaha yeah the old owner went hacking away at the harness and actually cut the fuse box out of the bike....and wired in all fuseable links!
     

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