I was looking around for another winter project to work on that I would be able to race for next year. I only have one bike in one class and wanted to be able to get more track time. A good friend of mine had a few bikes in need of some TLC and told me to pick one. We decided that his old Daytona he had would be a good start. It was missing a few parts such as the gas tank, carbs, wiring harness, air box, handlebars, throttle levers and cables and a seat. Most the parts that are there were fairly rough but not unusable. I had an idea of what I wanted to do with it and here is what I have been up to.
I started by ripping everything off the bike and cutting every tab and piece of metal off that was not going to be needed. The gas tanks was far to long so I shortened it up and glassed it back together. It holds water so I hope it will hold gas.
I took the engine apart to see what it looked like inside. Everything seamed tight and good but I had it apart so I started to port and polish the exhaust. I mildly cleaned up the transfer ports and intake.
I know you are not suppose to polish the intake, but I did anyways. I can’t help myself when I see a nice spot or aluminum.
I continued on and polished the cases and everything that was bare aluminum.
Once I was happy enough with the frame I painted it with heavy duty primer and a coat of black. By then the engine case was ready to go back in.
I finished off the porting and was just about sick of doing it. I decided to throw the engine back together and get on with moving forward. I stripped off the Yellow paint that someone had put on the lower forks. I ended up polishing them up as well. I have been working on the rear shocks and getting them cleaned up and ready for mounting. I am not to sure what to do about carbs yet. I have a set of 26s of a YPVS but I am not to sure how well they will work on the 400 now that it’s ported. I know the 400 uses 28s stock and I would possible like to fit 30s and a new set of TDR Reeds with spacers. Any Suggestions? I got a ways to go, but should be all set for Shannonville.
Dont forget to seal your tank with an epoxy,
alcool fuel and polyester resin dont mix well.
I buy my stuff from Fibre Citadelle, you should have something similiar in ont.
And dont use the cheap kream stuff.
Marc
Thanks Marc, I will make sure I look into that. Don’t want that gummy crap in the engine.
Mike
I threw the shocks and swingarm on today, they are just sitting on there right now. I wanted to see how it looked and check clearance and fitment with the reservoir. The old RD Shocks were toast, I had these ones so I used them.
I might use these rotors I had off another bike. Just so happens the bolt pattern it the same. I could drill and tap the other side and run a duel disk setup on the front.
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hi rgv.
if you want to test your tank for leaks?
you mix flour and water into a paste, then paint it onto the outside of the tank where you joined it.
let it dry. then buy a litre of varsol and put it in the tank and swish it all around the inside.
if you see any black spots on the flour mix after doing this? that tells you your tank is leaking.
hope this helped. good luck with your project.
graham #370
ps i have lots of rd400 parts if you get stuck give me a shout.
All Wired up an ready to go, Has tons of spark. Hope the CDI I have will work. Just need to wait on a new throttle cable and go get some gas. Fingers crossed.
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THE BEAST IS ALIVE!!!
Just need to get the fairing to fit so I wont need to worry about a place to put numbers or an oil catch pan. Not 100% sure what the fairing cam off of.
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Just finished up clearing the bike today. I painted my dads CB 550 while I was at it. He will be racing with the VRRA as well this year. There are some pics of that in here as well.