XS400 Maxim Kennys build - (pics hardtail/bobber)

My original post is below which turned into my build thread.
original pic of the bike as well

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Hey all,

Another post from the guy interested in welding. Last time it was about the seat, but now it's about the hardtail.

I abused the search function at the top of the forums, and didnt see what I was looking for - if anyone can provide me a link that would be great.

I might have found myself a welder... but he hasnt hardtailed a bike before. He is confident in his skills and agrees the saftey of the bike is utmost important.

Now to the question - assuming I work out a deal with this guy, can you point me to a thread on here that shows Hardtail
- specs,
- angles,
and materials used for such a project?

If its super easy for you guys to find, i will hang myhead in shame as my 'searching' skills will then completely suck

thanks again guys

-kenny

 

Re: Hardtail spec's -

Check TC brothers for a hardtail kit.

 

Re: Hardtail spec's -

exactly what im lookin for,
thanks Toreadorranger

 

Re: Hardtail spec's -

save this you might need it

 

Re: Hardtail spec's -

hahahahah snap!

 

Re: Hardtail spec's -

Did you ever get the TCBros kit? Were you happy with it? He shot me an email today and told me he wouldn't recomend any of his kits for a shafty. I'm thinking of sticking with 10" shocks instead for now

 

Re: Hardtail spec's -

TCBros wouldnt recommend one of their own kits ?

thats odd. i didnt order it yet, i was speakin with a guy who'd weld it up for 30 buck /hour. thought id try it out until now. maybe ill see what they think of their weld on hardtails,

you guys think it will work fine with a Yamaha Xs400?
(pic from front (sorry only one at this moment) at my other post
http://xjbikes.com/Forums/viewtopic/t=24936.html)

 

Re: Hardtail spec's -

Here is the email I got.....

Hi Matt,

I would advise against using my universal hardtail kit on a shaft drive bike. There is no need for axle slots on a shaft drive bike. Most people with shaft drive bikes just use solid struts to replace their shocks in order to hardtail the bike because you cannot stretch a shaft drive bike. Let me know exactly what you would be interested in ordering and I will get you a quote.

Thanks,
Tyler
TC Bros. Choppers, LLC
Ph: 419-265-9399
Fax: 866-652-3989
www.tcbroschoppers.com

 

Re: Hardtail spec's -

ahh, the maxim xs400 is a chain bike. the hardtail itself is for a xs650. i ebay messaged tcbros to see if theyd seen it on a xs400 at all.
what bike are you thinkin of puttin it on?

 

Re: Hardtail spec's -

Well, I'm not doing their kit now, but I have an XJ750 shafty. I'm not sure WHAT I'm doing now

 

Re: topic rename - Hardtail Options - (pics)

ok, well upon closer inspection,
my bike is weird.

again its a yamaha xs400,
here are some pics of the frame,

number 2 in the pic is a monospring, which hooks up to another heavy steel bracket which goes kinda the way of the line i drew,



here are more pics of the frame,


From the book


other angle


id be very open to suggestions on how do you think its best to hard take a bike like this? i was thinking (as above) maybe the preweld hardtail was the way to go (link below) but do you think i might just want some steel for the welder to remove the monoshock?


(weld on back end)
http://www.tcbroschoppers.com/store/ind ... ducts_id=9)

and another supplier for xs400 specifically it seems
http://www.pswcustoms.com/

thanks all
-kenny

 

Re: topic rename - Hardtail Options - (pics)

that's a weird frame. I'd do away with the whole ass end and use the TCBros weld on.

 

Re: topic rename -XS400 Maxim Hardtail Options - (pics)

i have the same bike, i am just gona take the monoshock off and weld in a piece of square stock and cut the parts off i dont need lol

 

Re: topic rename -XS400 Maxim Hardtail Options - (pics)

bingo! that is all you have to do. But you can just bolt it in instead of the rear shock so when your back cries mercy, you can throw the shock back in and return to stock. Search here for future49er or something like that. he did a 400 hardtail as did hoopty497 on the chopperfix board. It really is a piece of cake, just cut all the subframe off and start fabbing.

 

Re: topic rename -XS400 Maxim Hardtail Options - (pics)

dwcopple -ill take a look, see what they did. the main goal is to get the seat a few inches lower, (gf is short), so if its sitting at a 'hardtail' angle, i shouuuldd be able to get away with it.

layedoutcosta - you got any plans for immediate cuttin? i wouldnt mind seein the pictures and process if your doin it soon. lemme know!

as for the TCBro's kit - they emailed back and said they dont have a kit for an XS400, but told me to contact - http://www.pswcustoms.com/
I dont see a weldon from them, but it looks like they just did what your all sayin by killin the monoshock and cuttin the frame,

I'll take a look for future49er's post and see what i can find.

Thanks for the replies,

 

Re: topic rename -XS400 Maxim Hardtail Options - (pics)

I didnt realize that the 400 had such a different frame then the 650's. The TCbrothers kit is made for a single backbone type frame, which the 400 doesnt have. It would be difficult to incorporate into your frame.

I just installed one this weekend on my Kawasaki 400 but it has a frame similar to the XS650's.

 

Re: topic rename -XS400 Maxim Hardtail Options - (pics)

Reply from Prostreet, which i forgot i received the other day. Looks like TCBro's and Prostreet arnt gonna work - weld on tail wise,

Looks like it will have to be a 'universal' kit if anything
(still researching the other threads)
---



prostreetwarrior@aol.com to Kenny Napalm
show details May 8 (2 days ago)

Hello Kenny, our hard tails do not work with the maxim. At this point in time the best way to do one of those frames would be with the universal hard tail kit. The motor needs to be in the frame when cutting and welding to keep it str8. I hope this helps.
Sent on the Sprint® Now Network from my BlackBerry®


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Edit - Toreadorranger nice lookin frame there man. you did it yourself i assume?

** Another Edit - I found Future49er24's post on his Maxim,, looks like a long read but might be exactly the info i was lookin for - same bike it looks like

you guys are awesome thanks for the heads up and info -
http://xjbikes.com/Forums/viewtopic/t=10305.html

 

Re: topic rename -XS400 Maxim Hardtail Options - (pics)

ok, so, for any of you peeps on this thread with the XS400 like me,
do do do check out the post above this one -with the link. This thread is magic


Edit - with pics from other post


Before hard tail


With monoshock removed, and a bar replacing it,
also with Frame extra's cut

 

Re: topic rename -XS400 Maxim Hardtail Options - (pics)

ive looked at the thread probably everytime i get on this site, hopein that guy posts something, but i tink that bike is gone now, i could be wroung tho

 

Re: topic rename -XS400 Maxim Hardtail Options - (pics)

Yea, I did it myself. Was just alot of fitment. I used the stock swingarm as a "jig" for the new frame. Ended up with a 4.5" stretch.

 

Re: topic rename -XS400 Maxim Hardtail Options - (pics)

You should post up pics of the other projects when you find the threads.

 

Re: topic rename -XS400 Maxim Hardtail Options - (pics)

renaming this thread to my project build page i suppose? heh.

well, i got her running, and it really wasnt much, a new battery and fresh gas. i snapped a pic of the spark plug, i dunno how they look clean, but it didnt look all that rough. picture is bad - iphone quality,


also, here is how i suspect ill cut my frame, like future49r's up there (the red one) - shown as 1 in the pic below, and ill get a steel bar of proper measurements and bolt it in place,


this should give the low clearance i need for the lady to fit it. hopefully, i mean we tried everything else,

im gonna have to hit up the search here for solutions to the airbox and battery relocation, never thought of that

also you guys mentioned the TCI and the Voltage Regulator - are these those?


you guys find any flaws in the plan so far?

again much appreciated - as always
-kenny

 

Re: topic rename (again)-XS400 Maxim Kennys build - (pics)

1st flaw: your cut line would leave two tubes sticking up not attached to anything. you will need to cut where the swingarm bolt goes through instead.

2nd: Yes those are the CDI and V Reg. Mount 'em anywhere you want. just give em air.

3rd: Since it will be a rigid. Make/buy/fabricate a battery box and mount it on the flat spot in front of the wheel on the swingarm. That's where mine is.

4th: USE THE MINIMAL WIRING DIAGRAM ON HERE AND DUMP ALL THE UNNECESSARY RELAYS!!!

5th: Be original. No one like a copycat.

 

Re: topic rename (again)-XS400 Maxim Kennys build - (pics)

I like DW's idea about a bolt in piece of stock to replace the shock, then you could reverse it if needed, and even have multiple holes for different seat heights......

 

Re: topic rename (again)-XS400 Maxim Kennys build - (pics)

sounds good! guys like like the fact your helpin me out. i dig it.
first step is to get rid of the relays i think... and once i get a chance ill get the frame cut the way you suggested.
still unsure of the airbox.. but im gonna search that one on the forums, no worries there,
i will keep you posted with pics. wont be right away, but i will keep dedicated to it - thanks again

 

Re: topic rename (again)-XS400 Maxim Kennys build - (pics)

if you need pod filters. i have a set for your 400...pm me

 

Re: topic rename (again)-XS400 Maxim Kennys build - (pics)

If you have a guy willing to weld for you, then by all means, make your own hard tail. It's not hard to do. You've got the basic plan already. Tie in where you want to tie in. Cut off what you don't want. Simple!

 

Re: topic rename (again)-XS400 Maxim Kennys build - (pics)

i think thats the advise i needed hah. somethin gets ya a little nervous with somethin like this.
ill keep you all posted

 

Re: topic rename (again)-XS400 Maxim Kennys build - (pics)

i dont want this build to sound slacker - but im workin a band project on the side, so i have to dedicate time to both ya dig? but i did get into the garage, and started taking stuff off.

stuck on getting the airbox out, but it will probably come out once the monoshock is out. i unscrewed the bolt for the shock, but think i need some weight off the back wheel before i can pull it out. i'll need a hand with that, and it's 3 am right now, so im not gonna be gettin it . im a pretty small dude.
got the lights off, and some more covers, labeled the wires, cause ill need that. tryin to get the plastic mold out that was holding the fuse box... it can be cut with a hack saw, but with the shock gone it will be fine.


- can anyone tell me what these electrical parts are? just curious

part 1 - located by/with the positive battery cable, (two different angles)


(another part, there are 2 one blue and one red).


- also - i can rent the cutter from rogers rental. the welding of the new bar where the mono shock goes will be done by a pro - what do you think of a first timer usin the metal cutter on this sucker?

- also - got the pod filters from DW bein shipped soon - thanks again for those DW - ill let you know how it goes. gonna get a metal plate welded on the back for a bit easier seat mount options,

i ordered this seat as well..
http://cgi.ebay.com/ebaymotors/ws/eBayI ... 0536208083

i was thinking of these signals - should work fine eh?
http://www.d2moto.com/ProductDetails.as ... S111-CLEAR
i dont know much about the electrical, but the taillight i got (one of those limpdick styles) worked good when i plugged it in..

take care all.

-k

 

Re: topic rename (again)-XS400 Maxim Kennys build - (pics)

the seat and singnals look fine. I think I would have sprung like $30 more on the seat and went with the one that TCBros offer though. just looks like better quality.

 

Re: topic rename (again)-XS400 Maxim Kennys build - (pics)

Folks, i got the cuttin done.
First time using an angle grinder, bit spooky eh? nothin more bad ass than sparks flyin through the garage,

anyway, here are the cuts, and the 'mock up' with a cardboard seat, and my tank.

still waiting for the seat and signals, speedo, and pod's to show up. as well, im waitin for a call back from Calgary Metal over a bar i can bolt on in where the shock was.

also - im gonna say it, im a bit nervous about the electrical. i originally labeled the plugs as i pulled them out, but some of the tape came loose, and im noooOottt too sure what goes where for a couple of them. i dont much understand the electrical diagrams on here, so if anyone wants to enlighten me at all - id appreciate it.

again, cuts are a wee bit sloppy, but im happy with it


- guys -- thanks again for your support, and info - gotta say i cant take all the credit here when these forums are online


-kenny


-image removed by me to allow faster page load - older pics - let me know if you need them

 

Re: topic rename (again)-XS400 Maxim Kennys build - (pics)

I am looking to do the same thing with a 400 that I just picked up and I think after seeing this post I am going to go the same way as you showed in your pics above. I also thought of doing the tube steel idea to the stock swingarm and am sold on the idea now. The nice thing about bolting it in is you can get whatever height you want by where you place the holes when you mount it on. Thanks KennyNapalm for the insight and for helping me decide what I am going to do.
Now I just need to figure out how I can add forward controls to the bike. It makes it hard with it not having the frame that goes around the front of the motor. I may just have to fab one up.

 

Re: topic rename (again)-XS400 Maxim Kennys build - (pics)

oohh we'll call it even if you find a way, and send me a pic! hah, without the front of the frame i have no clue :S

 

Re: topic rename (again)-XS400 Maxim Kennys build - (pics)

I think I found a way today. I have a 650 frame sitting around and did a little measuring and I should be able to attach the lower part of the 650 frame near the neck of the 400 frame and attach it near the swingarm (with a few mods of course). I will let you know how it turns out.

 

Re: topic rename (again)-XS400 Maxim Kennys build - (pics)

why add so much weight for lousy forward controls? just use the front empty mount hole on the engine case.

 

Re: topic rename (again)-XS400 Maxim Kennys build - (pics)

kenny, ditch the gauges dude. also clean up the cuts a bit and grind the top remaining tube tabs where they are welded onto the rear downtubes. If you are using a grinder with a cutoff wheel just start on the outside of the tab and grind in then grab it with pliers and twist it off. switch to a grinding wheel and clean off what's left. It'll be worth it.

 

Re: topic rename (again)-XS400 Maxim Kennys build - (pics)

Angle grinders can be scary, just make sure your hands or other body parts aren't in the way in case it backlashes. I have a nice scar on my left hand from that. Just burnt the skin off in about 2 seconds or less.

 

Re: topic rename (again)-XS400 Maxim Kennys build - (pics)

Also put several layers of tape around areas your cutting/grinding so you don't damage anything else if you haven't thought of it already.

 

Re: topic rename (again)-XS400 Maxim Kennys build - (pics)

thanks for the replies guys,
2 seconds or less eh? im a thin dude too, i bet it will eat through me in less than 2 seconds easy

i had to return the grinder this morning to the rental place, but appreciate the suggestions, i'll end up taking DW's suggestions when my buddy with a grinder gets back in town, in a month or two (workin)



gauges are gonna go, yea for sure, i have a new speedo on the way so i'll wait till it shows up,
leavin the front alone right now, cause it's only gonna confuse me if i rip it all apart, heh. once i get the new signals and speedo, ill replace them at once,

also - question -- im talkin to a metal place in calgary just to get a new bar to replace the mono shock,
i received this reply -

" Do you know what material you need? I have some .188" 1018 square that may work but this is only mild steel. Cathy"

i assume i just need some Steel - but dont have an idea on gauge - will this work for my purpose or you think something heavier?

thanks again all

 

Re: topic rename (again)-XS400 Maxim Kennys build - (pics)

I would think that would be fine. The stamped frame looks like it isn't any heavier than 14ga. All designs are only as strong as its weakest point.

 

Re: topic rename (again)-XS400 Maxim Kennys build - (pics)

hey all,

im back with a long overdue update. not a lot changed, balancing work and the band. i guess i dont need to explain it tho eh? heh.
anyway,

hardtail worked. i bought a 15'' .188 gauge square steel bar. drilled and bolted in. its pretty solid. so far not a bad way to do it.


you can see tho, a mega gap where the tank mount goes.. so im thinkin a bit of extra bar drilled all the way through with a 3 in bolt. its not bolted yet, so its not straight in the pic,


tank is bigger than i remember? heh. and i took the gauges off (for dw hah) but the new speedo isnt bolted yet.


dont know if the seat i have is gonna fit.
the springs dont line up well with the aluminum back end. im gonna get a flat straight bar and bolt it to the back end, and bolt the seat to that bar.


dont know how the forward mount will go. doesnt seem to have enough room before the tank. i am aware the seat mount is on backwards. was thinking it would fit better where the back hardtail bolt goes in....

this sound like insanity to you guys or maybe have a better idea?
also my signals dont flash... it very well might be a grounding issue, but thought my temporary ground with electrical tape to the bar would be fine?
also im thinkin im not gonna go minimal. i really dont have the confidence to take on the electrical system at this point, better to hide the crap somewhere underneath instead.

as always all thoughts, opinions, and advice are welcome, thanks for lookin

 

Re: topic rename (again)-XS400 Maxim Kennys build - (pics)

alright here goes, lose the blinkers, you don't need 'em and they just clutter up the look. second, the swingarm is steel not aluminum, its just painted silver for some dumb reason. third, you need a rear fender, so flatten out an old front fender from a 70's bike or whatever and get it welded inside that swingarm. brace the end of it to the empty holes on the swingarm's rear junction by the axle slot. then you will mount your seat springs to the rear fender and put the mount on the seat correctly and secure it to your hardtail strut mount bolt. done and done.

 

Re: topic rename (again)-XS400 Maxim Kennys build - (pics)

thanks dw, i dig the reply.

i think i will keep the blinkers, unfortunately, cause of the law. i already ripped the mufflers off for a bad ass sound (well, as bad ass as 400cc will put out) and with the new 'sound laws' in calgary coming out - i'm already going to be darting the cops as is. without the signals, it will just give them more reason. sigh.

if thats steel - thats all good. i had a welder offer to put my rear fender on for 100 bucks... i thought that was a bit steep, but maybe you guys can offer input on what it should cost. i'd have to cart the bike down there too of course cause he isnt mobile.

sounds like a plan for the seat tho, all good all good.

oh ya, the speedo, heh, has 2 wires, a black and red. these do not fit the cable assembly that came off the old one. the old one had a block kinda plug in with 4 cables all going in at once.. suppose i have to cut and splice the old ones eh?

i'll keep you all posted on what's next.

 

Re: topic rename (again)-XS400 Maxim Kennys build - (pics)

Mate.. Get yourself a welder.. The should cost you about $200 or so for a MIG, or less than $100 for the old type, then you've no more welding bills.

Tack the steel under tank bar in place to practice your welding, then when you've got it just right, you can weld your fender in place, And tack those joints for the hard tail too.. Get enough practice and you'll be charging $100 a weld.

Looking food so far.

 

Re: topic rename (again)-XS400 Maxim Kennys build - (pics)

Just remember to take the tank off first or you wont have to worry about it anymore.LOL

 

Re: topic rename (again)-XS400 Maxim Kennys build - (pics)

LoL.. Bang!

 

Re: topic rename (again)-XS400 Maxim Kennys build - (pics)

yep, red is HOT and black is GROUND. get a $5 test light and you are all set. ground it anywhere metal or tie it into another in the headlight bucket. there are several in there.

 

Re: topic rename (again)-XS400 Maxim Kennys build - (pics)

The "old type"? Seriously? *shakes head in disbelief*

 

Re: topic rename (again)-XS400 Maxim Kennys build - (pics)

Old to me. I got my stick welder a few years ago. I got a MIG last year.

 

Re: topic rename (again)-XS400 Maxim Kennys build - (pics)

ok, another one of my 'once every couple weeks' posts.
got a welder coming in to help me out. i know you guys said buy one, but financially speaking, im not gonna use it after this (that i can tell) and id rather have some skill behind the welding gun - ya dig?

WElder shows up this Saturday. i got a back fender, and the tail light installed. Struts are made up, and ready to rock.

- he wants the bike on its side to weld, if this is not flexable, im good with draining the oil and removing the tank, can you guys think of anything else that might happen on its side?


i should mention, that the seat and tank will be bolted to another bar -some i have left over from the monoshock bar replacement. i'll layer it on top of the main support bar, a couple inches longer than the tank sticks out, and bolt the seat front to it.

and struts