RD400 Café Racer - Project Yamahaha...

[general_piffle]

Kicking off an RD400 café racer project, a bike I've hankered after since I was about 18 (back in the start of the last century).

So, thought I'd document it here. The actual work I'll be doing personally is minimal, beyond taking things apart, finding rare and unobtanium parts, finding people who can do different jobs - from paint to rebuilding carbs, etc. Sadly, without even a garage to my name and little to no spare time I'll be getting clever specialists to do all the hard work. What I do have though, is a very clear idea of what the bike should look like when it's finished.

Here's the start of it:

I have - second-hand parts that need refinishing/painting:

1.   Frame (any surplus brackets/bits/lugs removed and smoothed before powder-coating)
2.   Wheels
3.   Forks (progressive springs to be fitted)
4.   Petrol tank
5.   Side panels
6.   Spare gearbox
7.   Engine (cases, cylinder heads, cranks, etc.)
8.   Other miscellaneous parts

I have – new/reconditioned parts:

1.   Speedo and tacho
2.   Wiring loom
3.   Oil pump (completely rebuilt, delivering +10% extra oil)
4.   Tank cap
5.   Carburettors (completely rebuilt, will need re-jetting)
6.   Boyesen reeds
7.   NOS idiot light console (sits between clocks)
8.   Handlebar switches; both sides
9.   Rear-sets
10.   Kinked kick-starter
11.   Accu-Products chromoly swinging-arm (to be powder-coated same black as frame)
12.   Mini indicators (Posh Japan)
13.   Seat (café racer style)
14.   Fibreglass front mudguard
15.   Other miscellaneous parts

I need – the following:

1.   Y-boot air-filter (I’d rather not run a stock airbox, or individual pods)
2.   Hagon rear shocks (stainless steel, black springs, 330mm adjustable: 33025CSSB)
3.   Tyres
4.   Handlebar levers
5.   All cables/lines
6.   Mirrors
7.   Fuel tap
8.   Electronic ignition (let’s junk the points)
9.   Chain/sprockets
10.   Handlebars (medium/low anodised black Renthal superbike bars)
11.   Headlight
12.   Brake calipers and reservoirs
13.   Brake discs, front and rear (both drilled)
14.   Brake light (slim rectangular but tucked away, no big rear mudguard)
15.   Inner rear mudguard, to protect air-filter etc. (new only, can be fabricated)
16.   Expansion chambers – Higgspeed regular (no cans) upswept in satin black: https://higgspeed.com/product/expansion-chambers%e2%80%8b/yamaha/yamaha-rd250rd400-cd-models-1976-1977/ (ring-ding-a-ding-a-ring-ring!)

Some pictures for inspiration of colours/paint, and the sort of look I'm after...

[Mally]

Sounds good , was going to go down that route myself but more a period resto like a Sondel Sport , HamYam or FLF bodywork style replica, looking forward to seeing the results and following your progress, albeit via clever specialists  all the best with it.

[Nasher]

My take on it was full on racer style:

[robrd]

Sounds like a good project, I like you, like the period cafe race / race replicas. Here is a Yamaha R5 350 that I did a few years ago. Home made seat, tank, mudguards etc, this started as a pile of junk that no one wanted so I stepped in. A lot of hard work but worth every minute.

[Motty]

I will look forward to your updates, it's always very interesting how people view their own build.
Have you rummaged around the Restoration Section to see how other people have tackled similar projects?
Richard

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[general_piffle]

I will look forward to your updates, it's always very interesting how people view their own build.
Have you rummaged around the Restoration Section to see how other people have tackled similar projects?
Richard

Thanks very much Richard, yes I have been lurking for a bit and mooching around in different forum rooms. Also spent hours and hours researching online generally. There's another US forum called 2strokeworld.net, which has some useful info and interesting RD nuts.

I've gathered as much as I think I need for now. Am just waiting for the speedo/tacho to come back from a restorer. I'm going to de-rust and rust proof the petrol tank here at home with Bilt Hamber products, then get the tank, side-panels and new front mudguard off to Dream Machine for paint. I know paint is probably one of the last jobs to do, but I just want to get it done and as long as I keep them wrapped up it should be good.

[general_piffle]

Some 'before' pics. Just a pile of parts, for now...

[Mally]

I was the same had my paintwork for nearly 2 years before I finished the build , look forward to see what you go for , will be well done via Dream Machine for sure.

[general_piffle]

Quick question, are there any brake upgrades that keep the vintage look? I recall the brakes on my air-cooled RD250 as being 'interesting' and something with more stopping power would be great.

I've seen some use the R6/R1 calipers with a machined bracket, which I bet is very effective but I'm just not a big fan of the look. Thanks.

[Motty]

Some people use the twin calipers setup from a XS500 (although I'm not sure if all the XS500 came with twin discs)
Richard

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[german]

Some people use the twin calipers setup from a XS500 (although I'm not sure if all the XS500 came with twin discs)
Richard

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@Motty, the twin disk caliper setup is from the TX500. The predecessor of the XS500. In Germany it was available as an official upgrade for RD's at the Yamaha dealers. To use with the RD fork stanchions as the TX ones are longer.
Regards Uwe

[general_piffle]

How easy is it to fit the 35mm forks to a C/D model, is it just a straight swap?

[Colin Johnston]

Fairly easy swap, with the correct 35mm yoke. You will also need the front wheel & brake caliper to suit the 35mm forks, as they are different.
If you’ve got access to machining the original wheel can be made to fit with new spacers.


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