OllieB

Other folks with much more "XS" specific knowledge will probably chime in. I have some brake experience on bikes, scooters and cars, though. If the master cylinder you have is correct for the XS400, it should not be difficult. Once you have it mounted and the hose connected at each end and the bleed valve closed, fill the reservoir. I would use the new synthetic fluid usually marked as replacement for DOT 3/4. Don't use silicone fluid. It is not compatible with regular brake fluid. Now you connect the bleeder to the bleed nipple. Be certain the hose stays connected to the nipple. Some bleeders aren't that good and the hose comes off easily. Open the bleed valve about 1/4 - 1/2 turn. I usually hold one hand on the bleed hose/valve and use the other hand to wrench the bleed valve open. Begin pumping the vacuum brake bleeder. While you do want to suck brake fluid and air down through the system, YOU DON'T WANT TO EMPTY THE RESERVOIR, sucking more air into the system. As the level of fluid goes down in the reservoir, refill. Helps to have someone else to keep an eye on the reservoir. Once you think you have filled the system with brake fluid and purged all the air, close the bleed valve and squeeze the brake lever to see how it feels. As you probably already know, the lever should depress slightly then become firm. If it goes all the way down and/or feels spongy, you may still have air in the system. Sometimes with these tiny master cylinders you have to sort of prime them by squeezing the lever (holding it down), then open the valve slightly to allow air/fluid out. Don't release lever until valve is closed. May have to do this a couple of times. These systems are so small and move such a little bit of fluid with each squeeze that it is sometimes difficult to get trapped air out of the system. I have needed to use both the vacuum bleeder and lever squeeze method at times. Just cleaned the reservoir and flushed my XS400 system a couple days ago. Hope this helps.

According to the parts listing at BikeBandit (USA, Texas) the air filter elements are still available but are pricey at about $39 each, although cone filters may be pricey too. The service manual instructs you to clean the O.E. filters by blowing air through the filter material from the inside out. It also says that when the filter material does not seem to come clean using the compressed air method, that the elements should be replaced. I just inspected mine on my recently purchased '80 XS400 Special and the filter material seems to be some sort of fuzzy fabric material and appears to be relatively clean with 14,xxx miles on the bike. Could also have been replaced at some time in the past. See the link below for item #10. http://www.bikebandit.com/houseofmotorcycles/1980-yamaha-motorcycle-xs400sg/o/m8261

Mervin, Thanks for the clarification. Thought it would have the gasket. Haven't seen anything like it or near it's price here.

Here you go - found this UK website last night. They have a nice selection of NOS and repro parts at good prices, even with "across the pond" shipping. Fits XS500 1976-79. Does not specifically say it includes a gasket but you could ask the question before purchase. http://cgi.ebay.com/YAMAHA-XS500-XS-500-NEW-FUEL-CAP-/270473209065?cmd=ViewItem&pt=UK_Motorcycle_Parts&hash=item3ef975a4e9#ht_889wt_913

Dan, Since I have not seen a bike of your vintage, I don't know what the gas cap gasket looks like and if it is the same as on my 1980 XS400 Special. Actually, when I just checked my order and BikeBandit's site I realized they don't show a gas cap gasket for the 1980 version but show one for the 1981 version. My son has a 1981 XS400 Special II and the gas cap is exactly the same so I ordered the part from a 1981 XS. Below is the link to their site. Scroll down and look at part #25. It is difficult to tell from the pic exactly how the gasket is made. On our bikes, the gasket is grooved and must fit around a flange on the underside of the cap so the gasket is not just a simple flat piece of rubber. I consider this a safety item and should be replaced if cracked. Since these bikes have a pretty long life, it should still be supplied by the manufacturer. Maybe I am just spoiled - I have a 1990 and a 1977 Mercedes sedan and virtually everything is still available for these vehicles and, at reasonable prices. http://www.bikebandit.com/houseofmotorcycles/yamaha-motorcycle-xs400sh-1981/o/m8262

I just ordered one for my 1980 XS400 from BikeBandit.com. Little pricey ($22) but Yamaha didn't list one any longer.

kmac, Thanks! From other pics I have seen I thought so but that seems to be the only part that was not stock on the bike so I thought I would ask the experts. My son likes the cut down look and will probably do other mods to his XS400 but I want to keep mine stock with the classic look. Thanks for the link, too.

Hi, New to the forum and first post. Just got a 1980 XS400 Special a week and a half ago. Had a Baby Honda Dream 150 more than 40 years ago then a few scoots during the past few years - last one a Linhai Mainstreet 300. My son bought an '81 XS400 Special II about a month ago and I fell in love with it when I first saw it. Found a decent one in N. Central PA almost immediately. Went to see it and ended up hauling it home. I wanted one that was in fairly decent condition, not needing a total restoration before I could ride it. The bike had 14,2xx miles on it and was kept in nice condition for a 30 year old motorcycle. It is in good enough shape that I can ride it as is with very little to be done. Have put about 200 miles on it so far and it really starts and runs great. My plan is to do a "soft restoration" now - replace a few things such as brakes and rubber parts, anything else needing immediate attention, clean and polish it and enjoy the ride this Summer. Later, if I still want to, I will do a "hard restoration". The bike is in such nice condition that I could do paint touch-ups, a little re-chroming, the things mentioned above and leave it as-is. I am pleasantly surprised at how many parts are still available for this machine. One thing I will do soon is replace the tires - even though they have decent tread remaining. The front is Duro and the rear is Cheng Shin. I have had experience with both on scoots and know these do not give the best handling. Even the Shinko tires I put on my Linhai were dramatically better than the Chinese O.E. tires. I have read through a vast number of posts and learned a lot from this forum. Thanks to all who have contributed!!! One question: The front fender shown on the bike I took from my son's '81. My '80 had a bobbed one on it. The two fenders are not made the same. If you can tell from my pics, is this one proper for an '80? The side arms that bolt the fender to the tubes are stamped and part of the fender. The cut down one that came with my bike had aluminum side arms that were riveted to the fender.