BRB

I've seen a couple locally with asking prices of about $5k.

You should be able to find those jets at your local Yamaha shop.

My XS360-2D doesn't have canceling T/S, maybe you could compare your wiring diagram to the 360's.

Rim specs?

Then you will need a 2.5" rim to fit that tire (130/90)on the rear at minimum according to the chart. Does your rim have any size markings on it?

What size rims? Compare your rim size to Drewpy's chart.

There is a limit of tire size according to your rim size and also restrictions for tire size when it comes to chain rub, swing arm dimensions, etc.. If your going to retain the stock rim then you will need to install it and take some measurements. Next you will want to research maximum tire sizes that will fit your rim. Just remember that fitting a very wide tire on a smaller rim might work but will change the profile to the point that the intended performance characteristics of said tire will be compromised which in turn will compromise your handling characteristics.

The petcock kit you need should be the top one shown on the link. http://www.siriusconinc.com/search_result.php?make=YAMAHA&model=XS400&part=Fuel+Petcock+Repair+Kits&partno=&x=56&y=12&search=search As far as cleaning your carbs, a local carb rebuilding shop may have a ultrasonic tank (preferred) or you can by some Yamalube carb dip which mixes with water and a large second hand electric slow cooker (check the wattage, mine is a 475w) will do the trick.

I studied the pic a little closer and saw the battery box built into the the bottom of the seat pan. Electrics are probable mounted underneath also.

I really like the styling of your bike. Did you keep the stock battery box? I'm trying to figure out where to mount mine because I'm going with the open skeletal look and looking at the picture of the cafe that Drewpy sent I'm at a loss to where they hide/mount it. What is the length and brand of rear shocks your using? And is that a custom seat or a reworked of the shelf cafe seat?

Here is a link that might help you get in the ballpark: http://www.motorcyclecarbs.com/Motorcycle_Carburetor_Jetting__W7.cfm

I was thinking of buying the pod filter from Mike's for my XS360, what do you feel is wrong with them? The Uni pods are foam filters right? Can they be cleaned and how do they out perform the pods from Mike's?

You have to download your pic to a photo sharing site like photobucket and then copy img code and paste to your forum post.

Yes I see what you mean. Mine is slightly bent forward from vertical and your mount is angled back to except the Special tank. It shouldn't be that hard to fix, you might be able to cut flat plate and bend mount to except tank and weld. You might want to fab after you find the tank though. I found a decent '77 XS400 tank on eBay for about $40 shipped to use for my cafe seat cowl.

The top tube is welded into a cross brace. It is not flat but round tube (pipe). I think you measured back to far.