Old Lady...function over beauty

Discussion in 'Some Assembly Required' started by lord_oblivion, Jun 22, 2014.

  1. lord_oblivion

    lord_oblivion Been here awhile

    Joined:
    Sep 8, 2011
    Oddometer:
    166
    Location:
    On the Roads of Motherland
    I got this old school iron horse as a present from my friend.
    Neglected but running.

    It's CM400 Custom, 1981, 43HP.
    Missing side covers, gauges and headlight.
    Rear light, fender and turns are there but not shown in pic.

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    Electricals in very bad condition so that is first on list to sort :

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    Jawa 350 TS headlight and DIY headlights ears :

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    New H4 bulb and socket :

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    My (tm) Kawa EL250 fairing, hiding electrical spaghetti :

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    Over wires and connectors wil be alu plate covering all this hell and will cary DIY volt indicator, phone/gps cage and DIY phone charger, switch for DIY cop-like strobo (both LEDS white, not red/blue) and random electronics I made...

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    Next, seat pan :

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    I didn't like low seating position, so i'm decided to raise and level front part, but wihout welding and cutting, to preserve originality of frame :

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    Cheapest and dirtiest way is to fill it in with construction foam :evil

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    Then seat cover, no gluing no stitches, screwing it to pan is way quicker :D

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    So, next thing on the list are side covers. These will be fiberglassed from scratch by my friend.
    But before that, it's nice to put some luggage thingies. No passanger this time, so topcase can be moved toward front for better weight distribution.

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    Behind, just over stop lamp, is left dedicated space for tent.

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    Secondary, she will get sidebags carriers from my ex Honda (CB400N) :

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    and Yam XT600 front pegs, like on my ex CB :

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    She got new battery, slightly larger rear tyre (130-90-16, used but usable), new engine oil and oil filter and 5 liters of gasoline, for first test ride yesterday :wink:

    Despite bad visual aesthetics, seat is very comfy, sitting position like enduro, knees in relaxed 90deg position, back is right, shoulders relaxed.

    One more significant thing, I must change this wierd Jap handlebars. It feels like I'm driving [​IMG]

    :rofl

    and put some enduro bars (with risers), like from Transalp, XT600, Jawa 350 or such...

    To be continued :freaky
    #1
  2. JerryH

    JerryH Long timer

    Joined:
    Jul 4, 2009
    Oddometer:
    6,594
    Location:
    Chandler, AZ
    Back in '81, that was a beautiful bike, and all the bike anyone actually needed. I bought a brand new Suzuki GS450L back then, and thought I was on top of the world. The Honda CM400 Custom, Yamaha XS400 Special, and Kawasaki 440LTD were also great bikes. I would buy any one of them new right now if they were still available today.

    Looks like you did a good job on it. But the bars were my favorite part. They allowed a nice comfortable upright riding position.
    #2
  3. lord_oblivion

    lord_oblivion Been here awhile

    Joined:
    Sep 8, 2011
    Oddometer:
    166
    Location:
    On the Roads of Motherland
    Yes, on a straight highway. Impossible to do U turn, can't reach front brake with fingers properly etc.
    I don't like doing one-way modifications of original parts so her bars will be kept on pile for next owner.
    #3
  4. plugeye

    plugeye dreamer

    Joined:
    May 11, 2007
    Oddometer:
    5,312
    Location:
    Garland, Texas
    horrible bars belong to those who dont care about function.
    when you get some normal flat bars on, it'll transform the machine into something useful, functional and controllable.
    #4
  5. lord_oblivion

    lord_oblivion Been here awhile

    Joined:
    Sep 8, 2011
    Oddometer:
    166
    Location:
    On the Roads of Motherland
    Think of Scrambler ? :D
    #5
  6. lord_oblivion

    lord_oblivion Been here awhile

    Joined:
    Sep 8, 2011
    Oddometer:
    166
    Location:
    On the Roads of Motherland
    Little bit of iron work

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    And removable diy backrest on top case :wink:

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    On one pic, can be seen XT600 2KF front pegs. Also, I completelly removed rear pegs.

    Next, LED in top case, diy phone charger, LED rear light and LED parking lights/flasher, side covers and front roll-bar ...
    #6
  7. lord_oblivion

    lord_oblivion Been here awhile

    Joined:
    Sep 8, 2011
    Oddometer:
    166
    Location:
    On the Roads of Motherland
    New handlebars, handles and clutch cable :

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    Rear lamp ledilised (of some sort) :D, completely reversible to standard filament bulbs :

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    and phone charger mounted but no pics.

    Ultra-low cost scrappy side panels, but do their job :rofl

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    Bike fully loaded for a test ride.
    #7
  8. Andreja

    Andreja MotherThumper

    Joined:
    Dec 30, 2012
    Oddometer:
    48
    Location:
    Belgrade, Serbia, planning to move
    Ooooh, YOU stole my foot pegs? :rofl
    I can't wait for that 12 day ride :freaky
    #8
  9. lord_oblivion

    lord_oblivion Been here awhile

    Joined:
    Sep 8, 2011
    Oddometer:
    166
    Location:
    On the Roads of Motherland
    10 days :wink:

    Old Jawa 350 TS rollbar mounted :

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    and phone charger with volt controler :

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    #9
  10. L.B.S.

    L.B.S. Long timer

    Joined:
    Feb 26, 2010
    Oddometer:
    1,881
    So what happened to the CB400N? :D
    #10
  11. lord_oblivion

    lord_oblivion Been here awhile

    Joined:
    Sep 8, 2011
    Oddometer:
    166
    Location:
    On the Roads of Motherland
    Last year on end of July I returned her in original condition and sold her to my friend.
    I still see her driving around town :1drink
    #11
  12. L.B.S.

    L.B.S. Long timer

    Joined:
    Feb 26, 2010
    Oddometer:
    1,881
    :like: :D Good on you mate!

    That's almost exactly what I did with my beloved '82 CB450T, put her back to stock as much as I could, and gave to my best buddy for his very first motorbike.
    #12
  13. Wotsisname

    Wotsisname Banned

    Joined:
    Feb 7, 2014
    Oddometer:
    461
    Location:
    Arkanzoo
    It looks like a true adventure bike which could only be ridden by a true adventurer!

    (unlike the "pretend" ADVers who go out & buy a new BMW with heated grips & seat with the complementary Tutonic Grey riding gear to match!):rofl
    #13
  14. lord_oblivion

    lord_oblivion Been here awhile

    Joined:
    Sep 8, 2011
    Oddometer:
    166
    Location:
    On the Roads of Motherland
    My friend's first bike too (meaning, first bigger then 50cc chinese enduro) :evil
    #14
  15. lord_oblivion

    lord_oblivion Been here awhile

    Joined:
    Sep 8, 2011
    Oddometer:
    166
    Location:
    On the Roads of Motherland
    Some new details...
    Because original front brake master cylinder leaks at cap and o-ring beneath oil cup, quickest solution was to get complete another master cylinder, from ZZR600. This one came without cup cap and by coincidence old cap, lever and switch fits like butt on the potty :evil
    She got new brake pads and partially serviced break caliper.

    Tomorrow installation and testing.

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    #15
  16. lord_oblivion

    lord_oblivion Been here awhile

    Joined:
    Sep 8, 2011
    Oddometer:
    166
    Location:
    On the Roads of Motherland
    In the end, lever and hose did not fit so I was forced to replace them. Hose taken from scraped Tengai and lever from old Honda superbike. Now everything works as should, after additional disc cleaning :

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    #16
  17. lord_oblivion

    lord_oblivion Been here awhile

    Joined:
    Sep 8, 2011
    Oddometer:
    166
    Location:
    On the Roads of Motherland
    One more change, upped fairing and headlight and lowered turns, to make room for tool-bag and easier access to USB ports :

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    #17
  18. lord_oblivion

    lord_oblivion Been here awhile

    Joined:
    Sep 8, 2011
    Oddometer:
    166
    Location:
    On the Roads of Motherland
    Was on 13 days 'omnia mea mecum porto' camping trip in first half of August, 1700km, 80% tarmac 20% off :evil

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    So rear tyre came to this :


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    and it became necessary to replace it with Pirelli ST66 :

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    Bike performed flawlessly (for it's condition) during entire trip, except one-time allmost overheating on rocky uphill :freaky (not in pictures)
    #18
  19. lord_oblivion

    lord_oblivion Been here awhile

    Joined:
    Sep 8, 2011
    Oddometer:
    166
    Location:
    On the Roads of Motherland
    Forgot to post one of my farkels, 2.5 litre fuel reserve canister, mounted day before trip. Fortunately, there was no need to use it :)

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    #19
  20. lord_oblivion

    lord_oblivion Been here awhile

    Joined:
    Sep 8, 2011
    Oddometer:
    166
    Location:
    On the Roads of Motherland
    New LED eyes, straight from Aliexpress :evil
    Mounted last month.
    2*10 Wats, need some adjustment and eyebrows.

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    #20