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RD400 Café Racer - Project Yamahaha...

Started by general_piffle, November 14, 2023, 03:49:57 PM

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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...


LMS

#1
When I bought my 350 a year ago, I thought I would just fix it up some, done. Uhhh, nope. One thing led to another, next thing I know I have a cafe racer, so to speak, I guess. I did the same and searched for hours, looking for inspiration in regard to paint, etc. I learned so much from this board as I had no clue wtf I was doing. I wish I would have done what you are about to do, document the build in one place, oh well.
Besides the yellow race bike, I like the green bike best. Blue is my favorite color, but that seat is too bulbous, same with the pipes. But that's my opinion which doesn't mean jack shat. :)
Have fun!
75 RD350 bought 12/22. First motorcycle I have ever owned.

85RZwade

Sure be cool if you replicated Kenny's 0W48R, or at least as close as possible with a twin. Go big or stay home, right?
I post waayyy too much

general_piffle

Quote from: LMS on November 15, 2023, 08:22:29 AMWhen I bought my 350 a year ago, I thought I would just fix it up some, done. Uhhh, nope. One think led to another, next thing I know I have a cafe racer, so to speak, I guess. I did the same and searched for hours, looking for inspiration in regard to paint, etc. I learned so much from this board as I had no clue wtf I was doing. I wish I would have done what you are about to do, document the build in one place, oh well.
Besides the yellow race bike, I like the green bike best. Blue is my favorite color, but that seat is too bulbous, same with the pipes. But that's my opinion which doesn't mean jack shat. :)
Have fun!


Thanks! That's the thing with any bike, you always think 'oh, I'll just change this one thing...' and it never happens. It's often one thing after another!

Colour will definitely be the classic yellow with black and white graphics, but with a subtle twist I've got planned. The general look will be more like the green bike. But let's see how it unfolds.

general_piffle

Quote from: 85RZwade on November 15, 2023, 03:25:44 PMSure be cool if you replicated Kenny's 0W48R, or at least as close as possible with a twin. Go big or stay home, right?

The pic of KR's bike is just for colour. I'm going to keep it without a fairing, closer in look to the green bike.


But yes, it will be very far from original! It's nice to have the freedom to put together something I want, and not worry about 'market value' or saleability later on, as no doubt I'll just keep it. So, no need to consider any potential buyers 😉

general_piffle

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


m in sc

thats a good start!  :clap:

would HIGHLY recommend the fz1000 rotor/blue or gold dot r1/r6 caliper upgrade to the front brake. rear brake stock is fine on these w a disc.


general_piffle

Quote from: m in sc on November 16, 2023, 09:14:19 AMthats a good start!  :clap:

would HIGHLY recommend the fz1000 rotor/blue or gold dot r1/r6 caliper upgrade to the front brake. rear brake stock is fine on these w a disc.


Thanks for the tip! Is it just a straight swap, or are brackets etc. needed?

m in sc

brackets, easy to make. theres a thread on here


85RZwade

And brother Evans can hook you up with a caliper  :thumbs:
I post waayyy too much

general_piffle

Thanks guys, regarding brakes I've taken a look and I can see how effective the R1/R6 set-up would be. But are there any, better than stock, alternatives that still keep the vintage look?

general_piffle

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

m in sc

THE 35MM forsk themselves wont make a difference. IMHO, the stock dual piston early caliper was a great unit (so up to 78). fit it with a 14mm master and i'll lock the wheel up if you wish to and have a a great feel. .02