Rebuilding A Yamaha XS400 engine start to finish! This engine needed some major help as it had sat for a long time and apparently got water in it causing some corrosion and sludge. The engine had been ran with a blocked oil pickup screen causing early signs of oil starvation on the small end of the connecting rods. They got hot and caused damage to the piston pins. We went through the entire engine stop to bottom and now it is better than new!

Repaired damaged case
Sandblasted cases
Repainted
Fresh hone/new rings
All new bearings
Honed small end of connecting rods/new piston pins
All new gaskets/seals

0:00 7:15 Engine disassembly
7:16 11:39 Case Repair
11:40 15:20 Honing the cylinders
15:21 26:05 Painting engine pieces
26:06 28:36 Lapping valves
28:37 29:48 Masking for paint tips/tricks
29:49 32:01 Engine bearings and transmission assembly
32:02 34:31 Paint filling side covers
34:32 38:59 Assembling cylinder head, installing crankshaft
39:00 39:30 I'm an idiot
39:31 44:42 Marrying cases, checking ring gap, installing pistons and cylinder
44:43 45:53 Installing engine in bike
45:54 52:14 Installing cylinder head, cam, and rockers
52:15 56:19 Clutch and Starter
56:20 57:20 Outro

Video of rebuilding a starter clutch:    • Motorcycle Starter Clutch Rebuild How To  

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