1981 Yamaha XS400 Scramblerized...

[JimVonBaden]

Installed progressive springs and 20 wt fork oil, then fork gaiters.








Jim

[JimVonBaden]

Finished the paint on the tins. I put them on the frame to see how they would look, with the new decals, and to get them out of the way for the next phase, the motor!

















Jim

[Rick F.]

Jim,

It's definitely starting to resemble a motorcycle again--and a really nice-looking one at that!

Rick

[JimVonBaden]

Got started on the engine clean-up. Bonus, the ignition has been converted to electronic type.









Lots of work to get it pretty, but I have nothing but time, yeah right!

Jim

[JimVonBaden]

New Shoes, and socks!





Jim

[JimVonBaden]

Got back on the job for a few hours today. I am now working on the wheels. I removed the 16" rim and am swapping in an 18" rim for the rear. The old hub was grimy as hell, and the new one toast. So I despoked the new rim (rusty) and am preparing to use the old hub and new rim and spokes, new being new to me.

Old wheel:




New wheel:





Clean-up:




The spokes were very dirty with chain lube 20 years old, and some rusty. With some CLR and lots of elbow grease and a green scrubby, the spokes came out nice. I did have to sand down 4 of them. The plan is to Powder Coat the spokes and nipples, and paint the hubs, then polish the rims to chrome shiny. I want just a little chrome, so the front brake actuators, and a few other parts will be chrome, while most everything else will be painted black or yellow.

Jim

[bdimon]

I look forward to seeing the final product. From your description and the pictures so far, it will be a pretty motorcycle. Good call on the sparing use of chrome. A little always looks better than a lot.

[JimVonBaden]

Lots of prep has shown decent results on the wheels and other parts.

Spokes for the rear wheel:







Other wheel, engine and body parts done in powder:





Next I assemble the wheel and see if I can get it straight. My first time.

Jim

[bdimon]

Next I assemble the wheel and see if I can get it straight. My first time.

Jim

I remember putting a new hub on a rear wheel and lacing up the old spokes and rim. It was time consuming but not very difficult. If the 14 year old me could it, it will be a breeze for you, Jim.

[JimVonBaden]

I've been sick the last couple of days, so slow work. I did assemble the brakes for the wheels.



New wheels coming from Mike's XS.



Jim

[JimVonBaden]

So, the new rims arrived, very quickly, so I decided to see how they would look.



Full of promise, nice and shiney!



With the hub in the center.

Over an hour of frustration and I still could not get all the spokes in. I watched several videos on it, and no help. Finally I decided to zip-tie the spokes into position and then introduce the wheel.



MUCH better. I cut each zip-tie as I fit them to the nipples, and it went on easily until the last 4 spokes. To get them into the holes I had to bump the wheel on the floor on the opposite side, on some rubber matting, and the last 4 went right in.

Then I snugged down each nipple.

I checked with a screwdriver and the wheel was close to true, maybe 2mm off and no out of round.I will use my balancer to check and adjust it tomorrow.

Looks pretty good. I will need a little touch-up on the paint, but it was my first wheel lace, so I am OK with it.




Jim

[JimVonBaden]

I broke two spokes taking apart the front wheel, so I am stalled there, but I did order a new set. In the mean time, I did some more powder coating.







I did get the rear on the stand and ready to true, but I lost my spoke wrench, so it will wait until the new spokes come in for the front, and the new tool.




Then I cleaned up the colossal mess in the garage.

Jim

[Rick F.]

Jim,

Wow, great work on the wheel. I must say that you're a braver man than I am--I have an irrational fear of even trying to adjust a wire wheel on a bicycle, let alone redo a motorcycle wheel from scratch!

The powder coating looks great. How's the engine coming along?

Rick

[JimVonBaden]

Jim,

Wow, great work on the wheel. I must say that you're a braver man than I am--I have an irrational fear of even trying to adjust a wire wheel on a bicycle, let alone redo a motorcycle wheel from scratch!

The powder coating looks great. How's the engine coming along?

Rick

Thanks Rick!

We will see how it turns out!

The motor is coming along slowly!

Jim

[JimVonBaden]

Both wheels laced and trued. The first took about 3 hours, the second an hour. It helps when you know what you are doing somewhat.







Less than 1mm variance side to side, and .5mm hop. Not too bad for the first time.

Jim