Project Yamaha XS400 Bobber

[Mizer]

Just picked up this 1981 Yamaha XS400. Its a runner but not registered, previous owner had it on club plates.

50k on the clock, everything works as it should, this model came with the electric leg in addition to the kick start.

First up will be a run over the pits after I get a new rear hoop and tidy up a few small issues.



I had been looking for a project for some time and then this came up. I had initially wanted to go down the Cafe path but on further research found some great examples of bobbers and choppers and I was hooked.

This build is my first and I imagine it will take a long time, so let the fun begin.

This is the style I am chasing and my inspiration for the project.

[RiffRaff]

Subscribed. Good Luck

[brethren22]

yeah good base to start with. short shocks and a chop job on that back end should get you moving in the right direction. that SR is a good source of inspiration too, good luck with it!

[RIPLEY]

Sweet love bobbers good luck with it, i must say tho it looks particularly lovely and original it almost seems a shame to chop it when ther are so many dogs out and about.
Japbobbers.com is a great site as is xjbikes.com they have a other yammys section.

[Triple]

Hey mate, I've got a barely used Haynes workshop manual here if you need one...

[Mizer]

Sweet love bobbers good luck with it, i must say tho it looks particularly lovely and original it almost seems a shame to chop it when ther are so many dogs out and about.
Japbobbers.com is a great site as is xjbikes.com they have a other yammys section.

Yeh it is a great example, tho its my dream to Bob......I hunted for 2 years to find a good example as I wanted to start from a good base.

Hey mate, I've got a barely used Haynes workshop manual here if you need one...

Would be awesome Triple.............................PM sent.




I plan on starting a few bits this weekend.

[DJ Vieyra]

Good luck with the build!!

I have a XS250 and XS750 in case you need anything just holler!!!!

[Mizer]

Good luck with the build!!

I have a XS250 and XS750 in case you need anything just holler!!!!

Woo Hoo, cheers for the heads up.

[fatoxious]

hell yeah, nice one man. good luck!

[Mizer]

Got some work done on the bike over the weekend in readiness for the pits inspection Tues

Oil Change
New rear tyre fitted by hand, old enduro skills come into play.
Sorted the Tacho, if this passes the pits I will explain
Secured the seat, dodgy of course.
Degreased the beast and gave her a good clean.

This is where she is at now, all going well it passes inspection and the real build starts.

[Superdeuce22]

Lookin' schmick bro

[RiffRaff]

New rear tyre fitted by hand, old enduro skills come into play.

With those skills, I reckon you should get a job in the tyre industry cob!


Looks good

[Mizer]

Well the bike failed inspection today for steering head bearings and an incorrectly adjusted chain and rear drum brake (tho they appear fine to me)

No biggie it could have been pinged for a whole lot more I suppose.

Now to order the bearings, then adjust up the chain and brake for another try

[Vosy]

Knit pickers

[Mizer]

Pulled the front end apart and the bearings went every where, found them all but one. Was a new one for me as I have only ever replaced caged bearings in dirt bikes.

soooooooooooooooooooooooo

How close should the bearings be when sitting in the race? to me there is a lot of play like I could fit 1/2 a bearing in (if that makes sense)

The bearings and races appear fine to me but I am going to replace them anyway since its apart, manual says 1/4 balls.

Pics of the mess to come.

Still cant figure out their issue with the chain, any tighter and there is no play.

[Tbird tracker]

If your going to replace them anyway, you should consider tapered roller bearings. I'm sure there would be a kit available for the XS250, they will be a better setup and much easier to install as yo know from your dirtbikes.
Nice original bike by the way, I'll be following with interest.
Oh, to answer the question , about half a ball bearing of free space with all the balls fitted is about right. This is to avoid any chance of the balls binding against each other as the grease wears.

[Mizer]

If your going to replace them anyway, you should consider tapered roller bearings. I'm sure there would be a kit available for the XS250, they will be a better setup and much easier to install as yo know from your dirtbikes.
Nice original bike by the way, I'll be following with interest.
Oh, to answer the question , about half a ball bearing of free space with all the balls fitted is about right. This is to avoid any chance of the balls binding against each other as the grease wears.

Cheers,

Think I will put the ball bearings back in just for the pit inspection and replace with roller when I rebulid after the strip down for paint.

[Mizer]

OK so I went for the second inspection, guy passed it straight away.

Off to get the rego, am now told at this point I need proof of purchase from previous owner. Faaaaaaaaark me! emails, faxes and phone calls latter all sorted.

So she now has a spanky new plate and I can legally take her for a spin.

Prior to running it over I sorted a few problems and some in true dodgy style.

Cable tied the seat down as the retaining latch is worn beyond repair.

Purchased some new loose ball bearings for the steering stem, cleaned up the existing races then greased them up. Dropped in the new bearings and put the front end back together. Jumped on eBay and brought some roller type bearings for the actual rebuild.

The tacho cable on the bike was screwed and to be honest the gauge looked like crap, I had no intention of running a tacho so the solution was easy. I pulled it apart and binned the guts, then simply painted the back of the glass black and put it back on the bike.................what tacho? it never had one

I may be tempted to ride her for the next month or two before the strip down ........

So that’s all sorted, now for the next phase.......

[Tbird tracker]

Good work getting her rego'd, now let the fun begin!!

[Superdeuce22]

Any updates?