Author Topic: CB400 Four to XR400 Four (Read 50896 times)

Pezz · « **Reply #100 on:** January 24, 2011, 04:23:56 AM »

Its a blast with a few problems.

I am currently waiting on the price for a Dyna S Ignition and coils as it runs fine for 5 minutes then stops. sounds like condensors.

I have fitted an early XR250 front end and extended the rear swing arm 100mm hooked up with Ohlins off an old Husky.

I need fork springs to suit the additional weight. Can anyone give me a lead on a good fork spring supplier in the USofA?

Current springs
Length - 535mm
Diameter - 31mm
Wire Thickness - 4.30mm

as you can see above the ones I have have way too much sag.

Bike is around 170KG dry, Im 100KG wet

Retro Rocket · « **Reply #101 on:** January 24, 2011, 04:44:49 AM »

Have you tried Ikon in Sydney.?

http://www.ikonsuspension.com/content/product_ranges/fork_springs.shtml

Mick

Industrial Rat400f Killer · « **Reply #102 on:** January 24, 2011, 05:36:18 AM »

That bike looks like so much fun.

Pezz · « **Reply #103 on:** January 24, 2011, 04:40:24 PM »

Another Pic from taken by Tom of TBAM

FunJimmy · « **Reply #104 on:** January 24, 2011, 05:02:50 PM »

Very cool!
I really dig this.

Cheers
FJ

strynboen · « **Reply #105 on:** January 25, 2011, 07:06:34 AM »

hey..try to presure the front fork up vith air..just drill an valvet in top.and give it 5 bar..think it will lift it up

Pezz · « **Reply #106 on:** March 18, 2011, 01:54:59 AM »

Well I have been working on a few issues with the bike.

I picked up a Malcolm Smith Desert Tank which is now sitting on the bike, I have aslo fitted 50mm risers.

Clears everything and the Coils willfit in front of the tank!

Now to make the brackets and fit the Dyna S ignition and coils which arrived from Steve at Z1 Enterprises!!

I also fitted some heavier YSS fork springs, but they still seem a little soft. I will put the 30mm spacers back in to load it up some more.

Getting closer!!

MoMo · « **Reply #107 on:** March 18, 2011, 05:13:21 AM »

Haven't seen your build for awhile-it is really starting to take shape. Very nice...Larry

kiwi · « **Reply #108 on:** March 18, 2011, 06:03:12 PM »

yeah - looking good and taking shape - try pressurizing the forks as mentioned earlier - makes all the difference .
It reminds me of a pom i met here in the states - he was riding a super tenere with a fz750 motor shoehorned in , had 2 pannier tanks on it . I think he said he could go 600 miles between fill ups . He was riding around the world . It was a different world back in the 90's !!.

Pezz · « **Reply #109 on:** April 02, 2011, 03:50:27 PM »

Busy day yesterday!!!

Finally finished the Tank and Coil brackets. Just need painting

Also got the Dyna S installed and just need to tidy up the wiring which will take 10 minutes. All i need now is the tank taps and Im away

I have tred not to butcher the 400's frame so used 3mm plate for the tank supports.

Had to cut around a few of the frame tags.

Dyna S Installed

Pezz · « **Reply #110 on:** April 27, 2011, 03:52:10 AM »

Well we ran the 2011 Scrapheap Adventure ride over Easter, raising over $55,000 for Down Syndrome.
Unfortunately Yajyuu didnt get far, running like a peach, fuel tank leaking like a siv

I had a bit of fun with an old 620LC4 rear guard to make a 'Rallye' fairing, but the Malcolm Smith Desert Tank split near the top tank mount and covered the top of the motor and the high tension leads so no road trip ensued

I will be talking to a mate who builds alloy fuel tanks and sending him a nice chunk of cabbage for a new tank.

It will be sorted, really it will.

Finished here, not 20 feet later

MoMo · « **Reply #111 on:** April 27, 2011, 09:34:56 PM »

Too bad on the tank and good work raising money...Larry

Syscrush · « **Reply #112 on:** April 27, 2011, 11:57:42 PM »

I love the repurposed fender as fairing!

Pezz · « **Reply #113 on:** April 30, 2011, 08:56:45 PM »

Well, since the latest unsuccessful launch, I have been contemplating my navel flint and options to move ahead. Looks like it may be better to take 2 streps back and then on forward. I will scrap the Plastic tank! Relocate the coils to the original place, the get the second steel tank I have and take the whole bike to a tinsmith we have about 500k's from here. Get the steel tank modified with recesses for the forks and make it a bit bigger abot 20 litres

Pezz · « **Reply #114 on:** January 05, 2012, 10:20:26 PM »

Now I know this bike has a bit of a reputation as a trailer queen, hopefully it has had a change of heart and will surprise even the biggest Skeptics . . . !!!

Having Just arrived back at Skunkworks HQ for some further fettling . . . .

To Do list:
Put wiring back under the tank
Repair Fuel Tap
Fit up Oil Cooler
Replace the chain. I was supplied a Sun Fun Chain, which have an earnt reputation for snapping

remover the Big black blob, aka Seat, build a single seat and rack on the back
Ride the sucker

Here is the cutouts on the Fuel Tank to give me some steering lock

Pezz · « **Reply #115 on:** February 16, 2012, 02:42:08 AM »

Well I have been fettling away and have made a number of new additions.

So Far I have mounted a rear rack, fitted up the oil cooler (photo to follow)

Rebuilt the Fuel Tap, mounted the coil Brackets . . . .

Anyays the good news today is I have, with the help of Ray Tollhurst out at Camden Airport, made a new single seat base. Thanks so much Ray!!! Legend :thumb

I have always built this bike so it could be returned to a stock CB400/4 when it was finished. I didnt want to destroy a perfectly good steel seat base so I had to make a new one.

By fitting a rack on the back from an old Suzuki Ag bike, meant the seat had to be shortened. I could have gone into the process of making a mould but as I just need a simple copy and the steel base was pretty thin I just overlayed the fibreglass over the top.

So here goes a simple description of the process.

I had to remove all the glue, foam etc from the old base then tape any holes so the resin wouldnt run through.

Next we had to make a fence for across the back of the seat and fill all the holes with plasticine so they wouldnt fill with resin. The polish the whole area with mould release wax

Next was the PVA mould release, which is like liquid glad wrap.

Now we have a very nice shiny poliched and PVD's seat to lay the fibreglass resin on.

Laying up the glass matt, 2 layers of 0.5mm and 2 layers of 1.0mm.

Rolling to get the air out.

While it is still a little damp, trim around the part with a stanley knife

ready to come off the seat base

lifted off quite easily, and I can see all the locations for the rubber grommets and seat hinge and seat catch to be drilled and bolted on.

Seat sitting on the bike. really happy with it so now, fit up the spacers and hardware, then off to the trimmers.

MoMo · « **Reply #116 on:** February 16, 2012, 04:43:30 AM »

Nice tip on seat construction! Wish I could see the finished project...Larry

Pezz · « **Reply #117 on:** March 15, 2012, 03:20:58 PM »

Well the seat is away getting recovered!! Unsure what colour it will come back as the fellow is doing it for nix, and has suggested it might be a bit out there???

Thought I would show the hardware installed in the Fibreglass seat base. As the imprint of the steel base is on the fibreglass made it easy work.

Okay, in keeping with the theme of this bike, form over function, I have done something I wouldnt normally do, Honest!!!

Mounted the oil cooler on the side of the steel fuel tank. The bolts are spot welded and silver soldered to ensure a good hold. I then made brackets that have the leading edge out further the scoop in the air. The cooler has four rubber mounts to absorb the vibrations.

flame away

Pezz · « **Reply #118 on:** March 22, 2012, 04:46:57 AM »

Well the seat was delivered back, after a 10 hour ride from Queensland. I reckon Shane just wanted to see the look on my face.

I got this pic of the seat with the foam added

thinking this will be nice.

Well he sent through a few phone pics and I began to become a little concerned!!!

then he arrived with this

Close up to show some detail

Pilot Air Compressors had a stand at the Hare & Forbes 3 day sale and so we decided to add my XR460/4 to the display. Got a bit of interest too!!!

Actually, I reckon it suits it, although not really convinced about the quilting

Goofaroo · « **Reply #119 on:** March 22, 2012, 07:02:41 PM »

That bike was screaming for a solo saddle. Good move. As for the color and quilting- a matching tank bag would really make it pop.

It looks to me like thing would be fun as hell and I bet when you get it sorted it will be a great desert sled. Have you found any proper fork springs?

Pezz · « **Reply #120 on:** April 01, 2012, 02:34:29 AM »

Well it has been a busy week, and as Thrusday's departure approaches there are few things to tidy up.

During the week I was on the Pilot Air Compressors stand at the Burson Auto Parts Trade show. We had a great night and they had their pit girls walking around shaking everyone down for donations!! Will count it tomorrow but seems they did well!! Thanks Bursons and Pilot Air!!!

I tried to start it yesterday and no joy, sounded like no fuel and being a bit gummy decided to pull the carbies out for a clean. Its getting easier everytime.

Grace was quick to point out a clamp that needed tightening. My new Apprentice

I took it out for a longer ride today and it starts and runs well. I have gone from 75 to 85 main jets as 80's didnt come in the jet kit I was put onto.

With the mixture out 1-3/4 turns it was killing the flame, I have back it off to 1 turn out and it still gets a bit fluffy once it warms up. Will try 3/4 turn tomorrow.

With the lowered pegs it is jusy about perfect for me and I finally rigged up a hand rear brake, that works. very handy and the disc is a bit ordinary.

There has been a bit of overflow from No2 & 3 carbies but a tap with a screwdriver seems to get the seats to settle.

It is such a great bike to ride, light and neutral and cant wait for the 5 day Scrapheap Adventure Ride over Easter. Watch out for a ride report!!

Syscrush · « **Reply #121 on:** April 02, 2012, 11:32:00 AM »

Quote from: Pezz on April 01, 2012, 02:34:29 AM

It is such a great bike to ride, light and neutral and cant wait for the 5 day Scrapheap Adventure Ride over Easter. Watch out for a ride report!!

I can't wait! This bike is so rad. I wish you the best of luck on that ride!

JustinLonghorn · « **Reply #122 on:** April 02, 2012, 11:55:04 AM »

I am a fan, sir. I can definitely dig it.

magconpres · « **Reply #123 on:** April 06, 2012, 09:39:17 PM »

I was just in Sydney and picked up a motorcycle mag for the flight home. It included a Ballard's catalogue. Your bike was in it! Very cool indeed.

Pezz · « **Reply #124 on:** April 12, 2012, 06:52:57 PM »

I am writing a report but after much leakage of fuel from all 4 carbies, often taking turns, the old girl made to Scrapheap 3 with no real problems at all.

I will write up a full report over the weekend, and hopefully have some video to show too in the next few weeks.

News:

Author Topic: CB400 Four to XR400 Four (Read 50896 times)