Rehab 1977 XS360D

[robertmcw]

I bought an almost new red 1977 XS360 from my cousin in 1977 or 1978 and it didn’t have many miles with I got it. Call it #1. It did not have the push button for the starter. I can’t rember if #1 had a disk front brake or not. I remember a dealer had a used one with the push button for the starter and the motor in good shape, but the kick stand was missing and bought it. Call it #2. And the #2 was blue and the one I got from my cousin was red. So, I bought the second one and swapped the blue parts with the red parts from #1 to use in #2 and cut off the kick stand on #1 and had it welded on #2 and it was my go bike for many years. Go fast-forward. After many moves and many years, we finally found our forever home and moved #2 to my shop as had sold #1. I kept it covered in garages from when I got it but the last 10 years and it has been parked in a car port but not covered. Over the years rust began to take its toll. The last time I rode it was in about 2016 or so and stopped driving it as the vibrations hurt my feet and hands. So, I decided to redo it and bought a used drop in XS400 motor with the right bolt places for a swap as they are to run smoother, but the driver apparently dropped it as a few of the top fins and other parts were broken and put it covered until later. So, here are a photo of my project before it beings. So far, I have put a new battery with fresh gas, and it really started. I have fixed the front calipers; I have rebuilt the master cylinder and but am waiting to get new screws and parts to bolt it on. I have had the seat covered and have ordered a lot of NOS parts. I had given it to my son, but he lost the title and he really was not the motorcycle type, and he gave it back to me. I have sent off a new certified title so it can be sold when I don’t need it anymore. I have bought a set of NOS muffles as I love the look and the sound of those mufflers. I found the left NOS one years ago and have just found the right one and ordered it. I was very happy to find the right one as after looking for about 20 years, if not more the left ones was very expensive. Started it up last night and the right cylinder seems the carb was plugged as the right exhaust was cold but the left one was warm and gas smelled wrong. Then today would not start at all. They have a guy on eBay who rebuilds carbs and he did in 2016 for me so next off goes it goes next week. I have the forks and most of the parts to rebuild them as over the years, they got rusty. Re-chrome and repaint and some powder coat as needed to bring it back to 1977 as possible. I like the stock look so plan to rebuild it as close as possible AND see looking into have the XS400 motor fixed up to use it IF is rebuildable. Will post time to time so you can see the stasis of the project.

 

[robertmcw]

Well, I had put some gas treatment in the gas. Put about 1/2 gallon gas and 3 or 4 oz of B-12 Chemtoll last week and that is when it failed to start. Today tried and fired it up and both cylinders work. Is still rough but it starts. A carb rebuild is sitll in the list but not now. Ordred a few more parts for the brakes and groments for the side covers as the groumts are rock hard and the side cover pins both broke off and they need them to keep the side covers steady so they wil not flap in the wind. Have the parts to rebuild the master cylinder and already have rebuild the caliper so as soon the brakes work, will drive it to the driveway so can use the water pressurer to get 10 years of dirt and grease off to see what I will need to do next.

 

[robertmcw]

Have not had time to work on the scooter for a while but today I did. The master cylinder was toast. Remember, the last time I rode it was in 2016 and parked it as the vibration hurt my feet and hands. I had changed the tires probably in the mid 1980’s (?) and had changed the fork oil in the mid1980’s (?) and the rear shocks went with the bike. Thinking back, I was wearing tennies and no gloves. My bad. To get legal, had been looking to find a NOS master cylinder but they are not available. So tried a used one. Most have the internal parts are frozen with pits inside of the sleeve where you rebuild the piston. And the brake fluid reservoir tanks look horrible and new ones are not available for the XS360. Now the RD400 parts are a different story but that is not a story for today. So, while I was looking to rebuild an OEM XS360 master cylinder with in like new condition, I surfed eBay and found an aftermarket master cylinder and bought it thinking it may work. It was about $20.00 and the worst outcome would be to burn $20.00 if it does not work. Right? The lever is black and the brake light chord where it is plugged into the master cylinder is round (most of them do not have a chord and it has two terminals in them). The chord has a square connector to contact the headlight assy to the rear brake light and my setup calls for two bullet connectors to light the rear brake light. SO, had bought a NOS light chord from the master cylinder to the headlight assy and pulled the light chord from the aftermarket master cylinder chord and the NOS chord popped in just the NOS one does. Installed the bullet connectors to the head light assy. Turned the key on and the brake light worked. WOW. THEN I had a few OEM aluminum brake levers and pulled the black one off and installed the aluminum brake lever and worked great!!!! Did not install the set screw on the level on the photo but is there now. Did not fill brake fluid yet and have two boots on order that cover the banjo fittings as do not want to have to clean the mess again. It was a very good day. RM

 

[CaptChrome]

Is there a part number or description of the eBay part that you can share? I am sure others might be interested in this in the future if it works out well for you.

 

[robertmcw]

Done

 

[robertmcw]

I need to correct the part about of the master cylinder. I had the parts ready to rebuild it but when I took apart, I found the sleve was pitted and could not use it,