1981 Yamaha XS400 Scramblerized...

[JimVonBaden]

Now it is a roller. I did the zip-tie tire installation, but had to lever the last 6" on. I really like the tires and wheels. They looks great to me.






Back on the lift and out of the way for finishing the engine.



Jim

[JimVonBaden]

I've been cleaning the engine for a couple weeks now, and today the weather cooperated to paint it. Admittedly, I did not disassemble it, but it ran OK when I started to take it apart, so I felt it was worth a chance.





Looks better than my phone photos show.

Jim

[JimVonBaden]

New rear shocks, cheep like me.

The old ones:


The new ones:





No idea how good they are, but certainly better than the 35 year old originals.

Jim

[Rick F.]

Jim,

The Scrambler Project is really coming along! And it looks fantastic.

But why do I have the uneasy suspicion that, the moment it's completed, you're going to take this work of art out and run it through every water crossing and mudhole in the State??

Have fun with the final assembly!

Rick

[JimVonBaden]

Jim,

The Scrambler Project is really coming along! And it looks fantastic.

But why do I have the uneasy suspicion that, the moment it's completed, you're going to take this work of art out and run it through every water crossing and mudhole in the State??

Have fun with the final assembly!

Rick

More likely run it back and forth to work a few times, then sell it for a new project!

Jim

[JimVonBaden]

I'm not sure on the springs. I will measure them and report back.

Painted my pipes with Eastwood Header paint!

Before:



After:



Jim

[JimVonBaden]

Busy weekend so far. I needed to get the Yamaha at least trial assembled for the upcoming tech day so I could get it out of the garage and taking up space. Basically this is what it will look like when done. The wiring and a few other details are still waiting on more time by me, but I think it is pretty OK.

To get the engine in I laid the engine on its side and lowered the frame with wheels over it. I taped the frame to minimize damage while my lovely assistant helped me lower it over the engine.



One bolted in, I put it on the lift, then replaced most of the original motor mount bolts with stainless steel.


Then I started bolting on parts, all basically trial fitting. Most will come back off for final detail and fitting. Exhaust first:



I need to do something with the heat shields. I don't like them much and the fit is crap.

Next came the carbs and foot pegs, shifter lever and rear brake parts. And the instruments, headlights and rear light assembly.






Parked on the lift out of the way so I can clean up the garage for the tech day.




Jim

[Rick F.]

Jim,

Outstanding! And all the more so because you've personally repaired, tweaked, and/or powder-coated every single part on the bike, right down to each individual wheel spoke!

I know it needs another partial disassembly and final reassembly, but it's great to see what it will look like. As usual, I doff my cap!

Rick

[JimVonBaden]

Thanks Rick, I appreciate it!

Jim

[ela]

Badass.

[JimVonBaden]

Badass.

If it runs as well as it looks, I'll take that compliment!

Jim

[JimVonBaden]

Opened all the wiring up and started sorting wires and connections according to the wire diagram. Some of the wires were different colors, so I had to trace all of them to make sure they were correct. I also wrote down every wire and color and what it went to. Lots of work, but better at my desk in my office than in the hot garage trying to figure it all out.

Old wiring was a mess, and confusing. Missing lots of parts.






Wiring diagram from the XS400 forum.


New/used harness, likely from a different model as some of the wire colors are not right. But it should work. Removed the nasty and sticky electrical tape, then dug in marking all the connectors and loose wires.




Hopefully I got it all right. My only question is the generator/rectifier white wires. How do I know which wire goes to which wire, or does it matter?

Jim

[JimVonBaden]

So, 7 hours later, a little cussing, lots of testing, and the wiring is done. Don't mind what looks like scratches all over the frame, it is the loom material leaving greasy like marks everywhere. It comes off. I also discovered that I need side covers. The first realization was when I laid the pipes back in and realized the wiring is just an inch from the pipes. Then I saw how busy the wiring looked, so side covers it is!













Everything was tested and works, though I do not know for sure the charging system works. That will have to wait on the full reassembly.

Overall I am OK with it, not thrilled with the wiring organization, but I wanted full functionality. If I had left off the turn signals it would have been a LOT simpler.

Jim :cool

[JimVonBaden]

Now trying to decide if I want black or yellow side covers.

[bdimon]

I vote for the Yellow side covers. It's looking great, Jim. I look forward to seeing it on the road.