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rshutchinson
02-05-2015, 7:25 PM
Going with a clean white and pink-red scheme for my wife after seeing a clean white build on here by SGS. She is short and I think this is a perfect bike for her. She wants a small bike so this be a minimalistic build. Also will be powdercoating everything I can except for the frame since I can't bake that in a regular sized oven.

So I picked this up on christmas day for $200 not running. It's not seized and has compression so I'm sure I'll get it going. It's missing some things but most of the important stuff I'll be using was there, including 18" front and rear spoke rims with drums which I like. The throttle shafts were seized but managed to unstick them eventually with some heat and oil.

When I picked it up it came with a mag wheel since the spoked rim was seized up and not rolling. Also a Virago 1100 tank I think he said it was. Huge. It's going.

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/IMG_1680_zps3vxqt4au.jpg

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150103_142459_zpsqygvn2jy.jpg


Quickly stripped it down and removed the wiring.

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150104_121704_zpsvafaruog.jpg

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150104_121713_zpsndpljbdv.jpg


Went to a salvage yard and picked up this kz440 tank for $20. Going back to pick up odd's and end's I still need that I hope they have.

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/XS400/20150127_152544_zps3j1kynuv.jpg
http://i278.photobucket.com/albums/kk110/r-s-hutchinson/XS400/20150127_152533_zpsqw8zgexe.jpg


Now that I have the tank I'll be using I am hoping to make some quick work of this build.

Powdered the carb bodies in white.

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150202_110652_zpswldbtefu.jpg

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150202_110713_zpsspkqzjhu.jpg

Got the rest of the powder so I was able to finish up the carbs. Everything is powder coated on them, no paint. It's called Strawberry red, looks a little more pink than that to me but my wife loves them.

Also got the steel I need to modify the backbone for the new tank.


http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150205_200117_zpsxy7ppke8.jpg

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150205_200134_zpsp9w6zz1e.jpg

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150205_200219_zpsk0lgrb1d.jpg

rshutchinson
03-21-2015, 1:46 PM
Long time since I've really done much to the bike. Brought the engine inside cause it's way too cold outside. Had 30 psi compression in both cylinders and a wet test didn't help too much but a little.

Lots of dirt in the cylinders and valve seats. Exhaust port is full of scaly rust and dirt. Turns out the rings were completely seized in the pistons. After weeks of soaking in ATF/Acetone, many attempts of acid flux and a propane torch, boiling in water, boiling in ATF, I was not able to remove the top two compression rings. Only the oil ring. So I know what caused the low compression. I ordered a nice looking set of pistons on ebay. I've lightly honed the walls. Next up is to clean the head out and see if valve seats need to be recut. Will be ordering some new rings and gasket kit to put it all back together.

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/IMG_1739_zpscu7rdfr1.jpg
http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/IMG_1743_zpskeahauid.jpg
http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/IMG_1744_zpsdttqrskt.jpg
http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/IMG_1747_zps76kbb8ic.jpg
http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/IMG_1756_zpsis1wqfs3.jpg


Finally starting to warm up so I was able to get some frame work done.


http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/IMG_1764_zpscgsdyhe9.jpg
http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/IMG_1763_zpsvfhmx1rf.jpg
http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/IMG_1765_zpst57lze3o.jpg
http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/IMG_1774_zpsnitf2ahp.jpg

And I threw a seat pan on just for fun. Won't be going with a pan like that though.

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/IMG_1773_zpsflq0jbxf.jpg
http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/IMG_1772_zps5q1uaafw.jpg


Finished tying the tubes in together. I'm not sure if I like the rear tubes or not. I wanted to add a down bend to them but I don't know if I'll make some or not. Next is the backbone brace/top motor mount and cutting the rear off and bending up a hoop.

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/IMG_1781_zps4ae9ao47.jpg
http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/IMG_1786_zpsu161jxct.jpg
http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/IMG_1782_zpsofwrq7rt.jpg

rshutchinson
04-20-2015, 6:14 PM
Got the engine mostly back together. Lapped the valves, 1 seat had some rust but got it out mostly. Filled the chambers with water and no leaks so that is good.

Got a bunch of parts in but still waiting for a few things like signals, spokes, grips, levers etc.

Went with Avon Roadriders but a little saddened by how narrow they are for 90 and 100/90's compared to some Kenda's I've got.

Also decided to change the rear section of the frame since I didn't like it before.

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/IMG_1789_zpslzv9gi1j.jpg


Just need to set valve clearances and install sight glass and kick seal and the motor is done.

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/IMG_1792_zpsfizhrqln.jpg

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/IMG_1790_zpso1dvgu0e.jpg

thatdamnoakley
04-21-2015, 3:08 AM
That motor is sick. Good to see someone throwing some color on it that's not black or silver.

sdustin
04-21-2015, 4:10 AM
I love the carbs.

rshutchinson
04-21-2015, 6:09 AM
Thanks. It'll be mostly white with the red accents here and there. Though I'm stuck with some chrome pieces unfortunately like the spokes.

rshutchinson
04-22-2015, 5:15 AM
Yesterday I redid the rear section of the frame and bent a rear hoop with the oxy torch and some guessing. Wanted it to flow with the taillight I'm using and it came out pretty good and symmetrical. Today I'll be adding gussets and a crossbrace.

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150421_201520_zpsxpmtnvkk.jpg

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150421_201527_zpsz7jjlpvx.jpg

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150421_201626_zpsxyphmmvl.jpg

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150421_201645_zpslh3pmlzp.jpg

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150421_201825_zpsznjhq7xe.jpg

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150421_201837_zpsyqpflsbl.jpg


Turn signal since it's integrated.

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150421_201923_zpsfp4ihv44.jpg

billybiltit
04-22-2015, 10:33 AM
cool build man can't wait to follow along!

leon

rshutchinson
05-12-2015, 6:21 AM
As for the bike I got the frame all welded up. Working on the electronics try now.

Built a bigger powder coat oven so I can more easily do rims and *MAYBE* even some frames. Need to build an outside skin to it just to make it easier to move around but it works great. Gets to temp really fast with both elements working now.

Used a $10 steel filing cabinet and a $20 kitchen oven. Both I found on kijiji.

15" wide, 28" deep, 52" tall. Wish it were about twice as wide though, that's my limiting factor right now.

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/20150508_151333_zpsbr7tfu49.jpg

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/20150508_151344_zpse6mvo4va.jpg

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/20150508_151359_zpsjwwu060j.jpg

bparsel
05-13-2015, 8:50 AM
^^^^ Thats fucking cool man, I love to see homemade tools like that. Reminds me of the homemade flake blaster thread.

rshutchinson
05-16-2015, 1:05 PM
^^^^ Thats fucking cool man, I love to see homemade tools like that. Reminds me of the homemade flake blaster thread.

Thanks, it's quite a frankenstein machine but works awesome.



I also ordered some new RFY shocks since the ones on it were worn and the rods all rusted.

Rims powder coated and laced up. The red looks much more pink in the pictures.

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150512_153443_zpsrmuyfnxw.jpg

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150513_194650_zpsd96canch.jpg


Frame gussets and most of the electronics pan done. Going to add some small gussets to the rear tubes.

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150515_174433_zpsa0mq3wqv.jpg

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150515_174427_zpsjyxejxdh.jpg

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150515_174351_zpsacd0jurr.jpg

I also had to bend the rear hoop up more to get more clearance between the tire and the taillight.

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150515_174238_zpscrtfwrcv.jpg

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150515_174228_zpsfswv9yjp.jpg

Hammytime
05-18-2015, 12:55 PM
Got the engine mostly back together. Lapped the valves, 1 seat had some rust but got it out mostly. Filled the chambers with water and no leaks so that is good.

Got a bunch of parts in but still waiting for a few things like signals, spokes, grips, levers etc.

Went with Avon Roadriders but a little saddened by how narrow they are for 90 and 100/90's compared to some Kenda's I've got.

Also decided to change the rear section of the frame since I didn't like it before.

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/IMG_1789_zpslzv9gi1j.jpg


Just need to set valve clearances and install sight glass and kick seal and the motor is done.

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/IMG_1792_zpsfizhrqln.jpg

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/IMG_1790_zpso1dvgu0e.jpg

Hey, how did you mask off the "YAMAHA" lettering? Just tape or did you make a stencil of some sort. I'm currently working on my engine and wanted to make the logo lettering a different color.

rshutchinson
05-18-2015, 3:35 PM
It's powder coat so I did the YAMAHA first in the red/pink, then baked it, then sprayed the whole thing with white powder and with a wet finger and cloth I removed the white powder from the YAMAHA and baked. Then clear it all.

Riverofthepelts
05-18-2015, 4:02 PM
This looks awesome man. The engine and carbs look incredible.

rshutchinson
05-18-2015, 7:33 PM
This looks awesome man. The engine and carbs look incredible.

Thanks. Can't wait to be finished the whole bike.

OleDirtyDoc
05-21-2015, 10:21 PM
Sweet xs.

rshutchinson
05-22-2015, 6:17 AM
Welded up the mufflers, will be painting and then wrapping them later. Also, got most of the electronics and battery mounted. Will be moving on to the harness today.

Excuse the leftovers of my oven and filing cabinet powder coat oven laying against the house, have to get rid of that still.

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150521_174543_zpsbnvzafzy.jpg
http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150521_174550_zps4r3bpjnp.jpg

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150521_175452_zpsalfjooc0.jpg
http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150521_175505_zpscdjmqaoc.jpg

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150521_174736_zpsltsphfbg.jpg

rshutchinson
05-27-2015, 7:16 PM
Cut out a section of the bottom of the tray, then cut out some of the louvered section from the stove i dismantled for my PC oven and tacked it in. This should help promote airflow in there like you guys mention. I also cut a hole near the front and added a grommet to bring the wires from the engine in. too many big ones to hide in the frame tubing so that will have to do.

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150525_211335_zpswy2o3luj.jpg

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150525_211356_zpsjmqeueap.jpg

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150525_211427_zps8lxbnxh6.jpg

I welded some tabs to the frame and made up a plate to hold the reg and rec. Tucked under the engine and just above the bottom of the frame rails so it should get lots of air and still be somewhat protected. Still have access to all the drains and sump, doesnt cover much of the bottom of the engine and it comes off in a minute with 2 bolts. Best part is you'll never see any part of it with the exhaust and filter cover on.

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150527_160308_zpsxdfojwmc.jpg

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150527_160323_zpstnvhvawo.jpg

Exhaust mounts welded up.

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150525_211241_zpsbdfmgaxc.jpg

rshutchinson
06-08-2015, 7:16 PM
Made a seat pan.

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150530_101038_zpshdblgab3.jpg
http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150530_101048_zpsuht1midd.jpg

Then bought a meter of vinyl and some foam and made the cushion and covered it.

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150608_163537_zps8ciizmnd.jpg
http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150608_163619_zpswtve0mia.jpg
http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150608_164005_zpsnqjlmeqs.jpg

Made the plate mount, not sure if I like it or not but has no where else to go.

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150608_192425_zpsothhq6ow.jpg
http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150608_192416_zpsh6juwp2w.jpg

Adding some spools and finish welding tomorrow then I can paint and start to assemble.

OleDirtyDoc
06-08-2015, 8:29 PM
Damn that's looking sweet

rshutchinson
06-10-2015, 5:06 AM
Thanks. I cleaned up the frame yesterday, hoping to get some paint on it today if the weather cooperates.

rshutchinson
06-13-2015, 8:10 PM
Getting close!!!

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150613_074638_zps6oerbjol.jpg
http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150613_182523_zps09gczmpy.jpg
http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150613_182529_zpsy9eb9rzn.jpg

ichambers
06-14-2015, 10:57 PM
Cant wait to see this build complete! I'm digging the white frame.

rshutchinson
06-21-2015, 7:09 AM
http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150617_123728_zpszhtsdcb5.jpg
http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150617_123718_zpsrvngv37l.jpghttp://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150620_154805_zpssfrjjsig.jpg
http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150620_154751_zps1gibpgsp.jpg
http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150620_113848_zpsnfsg4cn8.jpg
http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150620_113818_zpscbfgaqai.jpg
http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/20150620_113810_zpsj1dqnojg.jpg

isabucket
06-21-2015, 7:05 PM
That looks great

Westboundbiker
06-21-2015, 8:11 PM
Holy cow is that amazing! I love it!

Hammytime
06-22-2015, 11:56 AM
Great job! Looks awesome!

billybiltit
06-22-2015, 12:51 PM
great job man!

turned out kickass

leon

cyberpvnk
06-22-2015, 1:42 PM
What is that monoshock beast in the background?

rshutchinson
06-22-2015, 4:31 PM
What is that monoshock beast in the background?

Thanks guys, it came out nicely for my first ever attempt at anything on this scale. Just a few odds and ends left on it. Completely rewired it which was intimidating at first but was really quite simple. Never heard this bike run so ill be excited when i can try it.

That monoshock in the background is my gr650 I got halfway through building before i decided to finish this xs first. Now that im nearing the end of this build i can get back to that. Ive got some progress pics of it in its build thread on here.

rshutchinson
06-25-2015, 11:58 AM
It runs. Carbs need to be dialed in but it starts up no problem. Have to get ownership, wheels trued and centered and finish a few small things before she can ride it though.

https://www.youtube.com/watch?v=gC9Ljre75q4

OleDirtyDoc
06-25-2015, 1:25 PM
Sounds sweet!miss mine.traded both for a cb750c

rshutchinson
08-09-2016, 12:38 PM
Long time since I posted here but have some little updates to share.

I was having battery issues with the bike. They'd develop a dead cell, sometimes within a few minutes and miles, others after 60+ minutes and miles. No smoke, no explosions, no bulging of the sealed AGM batteries, just a dead cell in battery. I added a ground from the regulator wiring directly to the frame, taped up the battery terminals and ran the headlight through relays rather than directly through the mini-switch at the bars. I have her leave the headlight on all the time now incase it was overcharging. That seemed to have fix that problem.

These Emgo shorties are just too loud. I've packed them with exhaust wrap and it's still very loud at anything past 4-5k RPM. I'd like to make a 2-1 for it but will require moving the reg/rec as I have them mounted under the engine.

The engine is burning (can't find any leaks on the ground so assume it is burning it) a fair amount of oil despite a top end rebuild. I'll take a more in-depth look at to make sure it's not leaking and if I don't find any I'll take it apart over winter to see what's going on in there.

I have since painted the front fender to match the tank and added license plate bolt lights.

List for over winter:

To do list for over winter:

Engine rebuild to see what is going on if necessary
Make a 2-1 exhaust and quieter muffler (maybe an M4 megaphone?)
Trail Tech Vapor gauge
New clutch fibers and springs
Do something about mirrors
New side stand spring

http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/IMG_20151008_143054_zpsnpzdqdny.jpg
http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/IMG_1925_zpsuoz1pnpq.jpg
http://i278.photobucket.com/albums/kk110/r-s-hutchinson/Katlyns%20XS400/IMG_1930_zpsxh292act.jpg

mikecola
08-11-2016, 10:30 PM
looking good!

81xs400cafe
09-02-2016, 3:24 PM
very nice im new to bikes and i recently picked up a 1981 xs400 and im thinking of going cafe racer styling with it

OleDirtyDoc
09-02-2016, 8:00 PM
very nice im new to bikes and i recently picked up a 1981 xs400 and im thinking of going cafe racer styling with it
Check out xs400.com

Moose
09-06-2016, 7:38 AM
Awesome build man!