Author Topic: Bat out of hell Build (Read 27406 times)

benjy · « **Reply #100 on:** May 05, 2012, 09:14:23 AM »

I'm open to correction,but I seem to remember old kawa z900/1000 pistons + their big bore kits will work in the 100 yammie

1980cm400t · « **Reply #101 on:** May 12, 2012, 01:49:03 PM »

Got a lot of work done today, the intake system is now complete. I used PVC pipe to connect the pod filters to the velocity stacks.

I ground down the inside edge of the pipe so it will be aerodynamic and gave it a light coat of paint to fill in any imperfections.

This should have all the advantages of the stock intake without any of the drawbacks here's how it looks.

1980cm400t · « **Reply #102 on:** May 12, 2012, 01:52:49 PM »

The tack and speedo mounting plate looked pretty good after a week in vinegar. It turns out the vinegar is also good for removing paint. I cleaned it up with some steel wool and put it back to soak for another week.

I also got the speedo, tack, and instrument lights taped up and ready for paint.

lucky · « **Reply #103 on:** May 12, 2012, 04:51:04 PM »

Mix the vinegar with 50% water. It will work even faster.

luhojs · « **Reply #104 on:** May 16, 2012, 02:19:04 PM »

Quote from: 1980cm400t on May 12, 2012, 01:49:03 PM

Got a lot of work done today, the intake system is now complete. I used PVC pipe to connect the pod filters to the velocity stacks.

I ground down the inside edge of the pipe so it will be aerodynamic and gave it a light coat of paint to fill in any imperfections.

This should have all the advantages of the stock intake without any of the drawbacks here's how it looks.

Like this setup. Very interested to hear how this works on the road

1980cm400t · « **Reply #105 on:** May 20, 2012, 12:45:07 PM »

My galfer stainless steel brake lines showed up. Unfortunately the front master cylinder (which i rebuilt) is still not functioning. I think the metal surfaces were ruined by corrosion because it won't seal. Given how cheap they are on ebay i'll probably buy a new one rather than try to rebuild it again. The Instrument plate looked good after a the 2nd week of acid soaking.

I painted it black like the gauges and put the whole assembly together

Really? · « **Reply #106 on:** May 20, 2012, 02:43:09 PM »

What made you go with the Standard tank versus the Special tank? Just curious. It looks as if that bike began its life as a Special, round everything. Many of the items on the Standard were squarish (i.e. tank, blinkers, gauges, etc...).

1980cm400t · « **Reply #107 on:** May 27, 2012, 01:53:56 PM »

The bike did start out as a special. I switched out the tank because the standard tanks hold more fuel they also have a more cafe racer look to them. More practicality and more style, I installed a kick starter for the same reason.

1980cm400t · « **Reply #108 on:** May 27, 2012, 02:09:32 PM »

The rear brake line I got from galfer is now installed. It fit the rear brake nicely and I got all the air out of the line. The line holding bracket was all rusted so I made a new one out of aluminum. I ordered a replacement master cylinder for the front.

I got the scull temporarily installed. I made the brackets out of aluminum angle iron which I bent into shape using a vice. The hardware I will replace with stainless steel once everything else is in place. I cut up a sheet of rubber to provide vibration dampening at all the points where metal is in contact with bone. The mock up seems pretty rigid which is good considering the amount of rubber I used. I think it will hold up.

1980cm400t · « **Reply #109 on:** June 03, 2012, 10:40:37 AM »

The foam for the cushion from foamorder.com showed up. It is next to impossible to cut with a knife without butchering it. Rather than get an upholstery saw I took the more economical rout and just got a cheap electric knife, it worked perfectly. I went with a cafe racer style seat, I'm still waiting for the leather to show up.

luhojs · « **Reply #110 on:** June 13, 2012, 02:55:27 PM »

Quote from: 1980cm400t on May 27, 2012, 02:09:32 PM

The rear brake line I got from galfer is now installed. It fit the rear brake nicely and I got all the air out of the line. The line holding bracket was all rusted so I made a new one out of aluminum. I ordered a replacement master cylinder for the front.

I got the scull temporarily installed. I made the brackets out of aluminum angle iron which I bent into shape using a vice. The hardware I will replace with stainless steel once everything else is in place. I cut up a sheet of rubber to provide vibration dampening at all the points where metal is in contact with bone. The mock up seems pretty rigid which is good considering the amount of rubber I used. I think it will hold up.

Now we're gettin somewhere..the skull is a major step towards the 'bat out of hell' theme. Looking good as well.
I like this project a lot...makes all of my projects seem almost normal...thanks..

1980cm400t · « **Reply #111 on:** July 07, 2012, 04:34:15 PM »

I just got a lot of parts in and a lot of work done. For starters I finally found a suitable master cylinder that didn't cost a fortune. I got a 22mm diameter piston model from Mikes XS (the original master cylinder was an 11/16" diameter piston). It did not come with a brake light switch so I got a double banjo bolt with a pressure activated switch built in. I bled out the system and it works perfectly now. The bigger piston is a major improvement, the brakes are very firm and I only have to pull the lever an inch to fully engage them. The brake line for the left hand line is a little long. I made some aluminum brackets to keep the lines in place and to take up the slack in the left hand line. I also stitched up some some leather for the seat. It looks pretty good given it my first attempt at upholstery work. The seat seems reasonably comfortable I won't know exactly how good or bad it is until I can take it on a long ride. I also got replacement handlebar switches and hand grips.

Mcwilliams570 · « **Reply #112 on:** July 08, 2012, 03:44:09 AM »

Looking good so far.. Where did you get the handlebar controls at I like them they look nice..

Matt

1980cm400t · « **Reply #113 on:** July 08, 2012, 07:54:55 PM »

Mikes XS, they are identical to the originals except they have on/off switch for the lights which is a nice bonus.

1980cm400t · « **Reply #114 on:** August 04, 2012, 05:40:11 PM »

The exhaust pipes have arrived, they are 2 into 1 headers. They came with mufflers but given the length of the headers I am going to leave them off. I made some aluminum brackets to clamp the back end of the exhaust to frame. I also got the fuel tank cover plate made and the tank kbs coated on the inside.

lucky · « **Reply #115 on:** August 04, 2012, 06:29:13 PM »

Clubchopper .com is the perfect venue for this build.

Put it in the forums>metric builds section.

It is looking very good!!!
But please take that cow scull off of it,
so it does not make the bike into a joke. LOL..lol

Mcwilliams570 · « **Reply #116 on:** August 04, 2012, 07:25:21 PM »

Quote from: lucky on August 04, 2012, 06:29:13 PM

Clubchopper .com is the perfect venue for this build.

Put it in the forums>metric builds section.

It is looking very good!!!
But please take that cow scull off of it,
so it does not make the bike into a joke. LOL..lol

Lucky did you bother to read this build and why it has the skull on it (you spelled skull wrong too) I admire this build is something different and takes some balls to pull off. I look forward to the finish product and find it in very poor taste that you say this bike will be a joke with the skull. Some people will get others wont but again read the whole thing and look at the F#$%ing album cover and then maybe you will have a understanding on why the skull is a major feature of this bike.

Keep up the good work 1980cm400t.

Matt

1980cm400t · « **Reply #117 on:** August 19, 2012, 06:28:59 PM »

I went to change the oils in the bike (engine, middle gear and final drive) and ran into a problem. The final drive filler plug was frozen in place and I stripped out the Allen head trying to break it free. Six drill bits, a screwdriver, and 2 screw extractors later I finally got it out.

I have a replacement on the way from bike bandit. I also addressed the middle gear to final drive bolts. I needed a crow foot wrench that is long enough to reach the bolts so I can put the specified torque on them. I bought a socket cut it in 2 and welded it to either side of a steel plate.

It fit nicely but in the process of installing the bolts I cracked one of the heads off. The only way to retrieve it was to pull the swing arm off and use a screw extractor.

It came out without a problem and I have replacements on the way, it cracked because I misread the torque spec in the manual and over torqued it.

While I had the swing arm off I repacked the bearings on the universal joint

Really? · « **Reply #118 on:** August 19, 2012, 07:49:17 PM »

Glad you got that worked out!

1980cm400t · « **Reply #119 on:** September 30, 2012, 11:07:13 AM »

The final drive is now installed as well as the dust boot. I'm glad I waited to buy the boot, the dealer price dropped significantly for some reason. The fuel system is now functional as well. Rather that rebuild the old vacuum petcocks I got new ones. The rebuild kits for the old petcocks cost as much as buying new universal petcocks and making adapters. I made the adapters out of 3/8" stainless steel and drilled and tapped them with a 3/8" pipe tap to accommodate the universal petcocks. They are sealed with buna-n gasket material.

I also installed 2 fuel filters (one for each side) and a crossover pipe that will prevent fuel pooled on on side of the tank from starving the other side's carburetors.

I also added a combined breather filter for the crankcase and middle gear oil. I used a soldering iron to weld the two different size hoses together.

I got some help making the new wiring harness which is now complete in terms of the starting and charging circuits. The engine started on the first turn and it sounds incredible.

I found out a few things while I had it running. The carbs are not right. I think by moving to a dry location with some altitude my initial guess as to the required jet size with the intake and exhaust modifications is too rich. The bike starts easily every time but bogs and shuts off the instant you open the throttle. Holding the choke on while opening the throttle seems to make the issue worse. The electrical system is working perfectly. I jumped it off a car to start it and once running it can be disconnected from the car battery and will keep running. It also puts out increased voltage when the engine is revved. Now its time to tackle the cosmetics so I can get this thing on the road

Killer Canary · « **Reply #120 on:** September 30, 2012, 06:06:46 PM »

Very original idea! That's a song that gets me revved. Your motor turned out nicely. Any idea what ponies a stock XS11 produced?

1980cm400t · « **Reply #121 on:** September 30, 2012, 07:51:52 PM »

95 horsepower stock probably more now.

Mcwilliams570 · « **Reply #122 on:** April 06, 2013, 08:38:52 PM »

Poke any update

1980cm400t · « **Reply #123 on:** September 29, 2013, 06:06:07 PM »

running into carburetor issues will update once I sort them out

Really? · « **Reply #124 on:** September 30, 2013, 11:45:47 AM »

Wonder if you put the stock airbox back on along with the mufflers, will it improve. Jet from there. Remove the swarups from the carbs if they are there. These are devices that were supposed to add a swirl flow to the mixture. Don't know if these were worth a darn or not. Had them in my XS Eleven donkey's years ago.

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Author Topic: Bat out of hell Build (Read 27406 times)