1977 Yamaha RD400D

EvilTwinz

Parts Cobbler
After carrying this bike around for decades through various garages, porches and stages in my life. It's finally getting restored. I bought this bike used back in 1986, while going to school, living in San Luis Obispo. It was in fairly bad shape trying to kill me, so I retired it somewhere around 1995. And it finally got broken down into boxes about 10 years ago. I've literally been buying parts for it on eBay, Craigslist and by word of mouth for the last 20 years or so!

I have always know that I don't really have the skills to build a 2-stroke engine, so after touch-and-go communications for a decade with an engine builder in Castro Valley, we're finally getting it done! I've recognized the fact that 2T non-electronic motors are a dying dark art and if I didn't get this thing built sometime soon, all the talented mechanics would soon be dead.

Over the years, I have gone through many design renditions in my head (and on paper or spreadsheets), but in the end, the bike will be a pretty good representation of how it looked when I first bought it many years ago. It's going to be Chappy Red with gold painted OEM cast wheels, the OEM brake system, original instrumentation, gas tank and sides. Some alterations that are being made are Woodcraft clip-on bars, racing suspension, a cafe seat (and rear fender elimination), cut front fender, modern signals and brake light. The motor will be mostly stock (almost all NOS Yamaha parts) with a 1979 Daytona head, Y-boot, intake crossover pipe, single K&N filter, and Barnett clutch output through a Factory Products Pipe exhaust.

I've already restored the forks with Race Tech internals and new seals. I bought Ikon (formerly Koni) shocks for the rear. We're in the final stages of the engine being built. This bike will be way better than when I first purchased it- I will finally get a chance to see what it rides like when it was fresh from the factory. I can hardly wait to get this bike completed!
 

1962siia

Well-known member
Nice! With the suspension upgrades I bet it will be even better than when it was new. Looking forward to seeing it come together! :thumbup
 

EvilTwinz

Parts Cobbler
This is how the bike looked 10 years ago, right before I picked it apart. At this point, it hadn't even been run for 15 years! I put it in non-op, then moved on. Since then, I've had a couple of SV650's and a Harley that I ride as a daily. Other projects just always seemed to come first.


Many moons ago, I crashed this here bike into the back of a car going down Hwy 17 from Santa Cruz to San Jose, right in front of the Lexington Reservoir. I was just a punk kid who didn't know much about maintenance, so the brakes didn't work very well. Everyone locked up their brakes on the decline and tires were smoking. I'm just lucky I'm not dead. Here is a better look at how bent those original forks were. The bottom pair were replacements I bought eons ago.


The Daytona head was in pretty bad shape. When I finally decided that this was the year to restore the bike, the head was the very first thing I tackled.


I'm not really familiar with metal polishing, so this took a bit of trial and error. Many different grits of sandpaper. A couple of different buffing systems. After about 6 hours of work spread over a few days, the head really started looking good!
 

EvilTwinz

Parts Cobbler
These are the same original fugly black fork sliders that were on the bike. I stripped off the black paint and went to town doing my polishing thing, trying to return them to the factory spec appearance. Before and after.


The forks got new seals and new Race Tech internals- gold valve emulators and springs. The raided the straight tubes from the donor pair that I bought. There was some surface rust on them, so I had to polish those out too. The triple clamps got some new paint. I replaced the old ball bearing headset with a taper bearing from All Balls.


The top triple got a little extra custom work. I knew that I would be mounting clip-ons, so I wanted to eliminate the handlbar riser mounts. A friend of mine already started the process by grinding them down. I completed the process by filling the holes with JB Weld SteelStik, then sanding them down until they were perfect. I'm very pleased with how they came out!


I took all the hand controls apart and gave them a good cleaning. Then I gave them a fresh coat of paint, along with the clutch perch. I was actually able to preserve all the original stickers on the controls! That polished clutch lever was purchased off eBay 20 years ago, and I have been waiting forever to put it on this bike!!!
 

EvilTwinz

Parts Cobbler
Now, the bike is really starting to take shape! Here, I'm just starting to do some measurements and to get an idea of dimensions, as I'm trying to fit on a new cafe-style seat. (That's the old seat.)


The headlight bucket has new paint, as does the instrument cluster and meter bracket. New light bulbs in the console and it's ready to go! I installed a Hella H4 halogen lens and put some super-bright PIAA bulb in there. That should help with night riding. The headlight rim chrome had some pretty deep scratches on it, so I took it to a plating shop in Hayward and just got it rechromed.


Here's a light mock up on the motor right before it went to my engine builder in Castro Valley. The cylinders were blasted, then painted. The side cases were cleaned, then painted. It's looking good!!


My garage in its sad state of affairs. I've always got a project going on in there. I'm really horrible about cleaning up after myself! That garage is always busy, busy, busy...
 

Johndicezx9

Rolls with it...
Please do! :thumbup

My first street bike was 1978 RD400E that I bought in July 1979.

Is that head with the shroud/ram air off a RD400F?
 

EvilTwinz

Parts Cobbler
Please do! :thumbup

My first street bike was 1978 RD400E that I bought in July 1979.

Is that head with the shroud/ram air off a RD400F?

Yes, it's a 1979 RD400F Daytona head. I always loved the way they looked and they were only produced for one year! I have no idea if it really has any better performance, although the domes are cut a little differently than the earlier RD400's. I know there are lots of cool heads out there- Webco, DG, the Revco water cooled heads, etc., but I really love this head.
 

EvilTwinz

Parts Cobbler

Pretty amazing build he has going! Yes, these restorations are a total money pit, if done right. My original goal was to do a TD3 replica racer, but as I went along, I decided to uncomplicate things by omitting the fairing for now (the fairing and paint alone would've been about $3K), but after more consideration, I elected to go without the longer tank. These bikes were already wheelie-happy and they really need more weight over the front of the bike.

He's easily $8K+ into the build. So far, I'm just around $7.5K, but I still have the paint job and the powdercoating to account for. Probably 95% of the parts on this bike are Yamaha OEM. I tried to rebuild what I could with NOS, including both brake master cylinders, brake calipers, pistons, rings, bearings, nuts and bolts. (I have just about 2 of everything- engine, frame, wheels, gas tank, oil tank, instrumentation, etc.- so I'm able to raid parts, and mix and match if possible.) Funny I should spend so much money on a bike that only cost me $400 back in the day :wow

These parts have been sitting around the garage in boxes for so long now, if I died, my wife would have no idea what to do with them, nor would she know what they were worth. So I figured I'd do her a favor and put the bike back together again. I have no intentions of selling the bike in the near future. I fully intend on enjoying it to it's fullest potential, including taking it to the track!
 

bikeama

Super Moderator
Staff member
Have great memories of my '77 RD400. I admire those who do full restores, just not what I want to spend my $$$ on.
 

Johndicezx9

Rolls with it...
Yes, it's a 1979 RD400F Daytona head. I always loved the way they looked and they were only produced for one year! I have no idea if it really has any better performance, although the domes are cut a little differently than the earlier RD400's. I know there are lots of cool heads out there- Webco, DG, the Revco water cooled heads, etc., but I really love this head.

I had the DG gold anodized radial heads, swing arm, & pipes by the time I was done, S&w shocks, and remember the air caps for forks?

Sold before I went off to college.
 

EvilTwinz

Parts Cobbler
I had the DG gold anodized radial heads, swing arm, & pipes by the time I was done, S&w shocks, and remember the air caps for forks?

Sold before I went off to college.

That sounds like a very sweet setup! So innovative at the time. Now there are DG head and swingarm knock-offs available. As for the pipes, back in the day, there weren't many options available, so DG pretty much got the business from their name recognition. When I bought the bike, it came with Bassani pipes, but those are long gone- I can't even remember what I did with them.

From time to time, I look for the air caps. They were pretty trick, but not really all that necessary if your suspension is set up correctly. But it would be nice to be able to change preload on the fly to address unexpected road (track) conditions!
 

auntiebling

megalomaniacal troglodyte
Staff member
Super bright light bulbs: if you haven't put them on a relay setup so they get the full battery voltage and you don't melt your wires

Looks good, I dont have that kind of patience
 

EvilTwinz

Parts Cobbler
Yesterday, I picked up the motor from Paul. It was awe-inspiring to see it assembled and ready for its next big steps ahead.



I was so excited that I ditched all my afternoon plans just to get started on stuffing the motor back into my frame. But first, I had to find all my engine mounting parts and give them a decent scrubbing. I am lucky enough to have two sets of mounts, because one of the front spacer tubes got slightly dented, so the bolt wouldn't slide all the way through. No biggie. Problem solved. I did discover that I happen to be one rear mounting bolt short. Apparently, I never did have that bolt in the first place....

The engine went in with little incident. I fitted the carbs on the manifolds and attached the Y-boot and K&N filter on there as well. I was surprised to see how high that air filter sits!! That thing would be halfway into my gas tank! There's no way I can use that thing.



Luckily, I had a shorter alternate air filter- one big fat foamie Unifilter. Originally, I had always planned on using the K&N, because I've seen them on past engine build pics and they always look so cool, but such a tall filter doesn't seem to be an option for me. After doing a little research, the consensus is that the foam air filters do a much better job in filtering particles (protecting your motor) and they flow better resulting in more power output! I'm sold!

So I swapped out the air filters. A much better fit, I must say. And I got my gear shifter bolted up just for the sake of appearances, as I know that I have to remove that side case again to install the new 520 chain.

Right now, I feel like this is the tale of two bikes. I'm building one for the DMV, so I can finish up the registration with the VIN verification process (which I'm starting to believe that I will need the brake light and turn signals to be functional). So I might as well just get the bike to run.

In parallel, I'm whomping on the other frame, cutting/brazing/grinding/sanding so I can get it off to the powdercoater. That entails getting the seat pan mounting done. At that point, I can send my parts off to Sacramento to get the parts painted.



And just when the project is getting exciting, I'm headed out on vacation at the end of the week! Plus work is dumping a shit ton of weird hours and shifts on me right up until the day before I take off! So the bike(s) will pretty much have to be put on hold [again] until I get back. :cry
 

auntiebling

megalomaniacal troglodyte
Staff member
excellent!

did you non-op it when you mothballed the bike? if no, might need inspections. if yes, should just have to pay fees and get new plates (if missing) and stickers. easy peasy
 

EvilTwinz

Parts Cobbler
I non-oped it back sometime in the mid 90's. I believe at the time the DMV was requiring everyone to re-up their non-op statuses every year or back reg will ensue. I neglected to do so. I can recall checking on getting the bike back on the streets some 15 years ago and the DMV wanted an astronomical sum of money to do so. Hence the second RD frame, complete with clear and current title.

But just recently I went back into the DMV to see what it would cost me if I tried to bring the original entire bike back to current reg. I went in with a bevy of paperwork, including the original non-op paperwork and past registration papers demonstrating that I was the true owner of the bike. The DMV policies have changed so many times over the years, and the workers there have no idea of history or past policies, so I was basically given a pass- only $180 to get it current! But I would have to bring the "complete" bike for a VIN verification to get it back into the system again. I'm not even sure they will accept verification from outside vendors, nor the CHP. She said it wouldn't cost me anything, just show up (no appointment needed, whatever that means) with paperwork and license plate, but they will perform a brake check. First I assumed it meant brake function check, but now I'm starting to think that they want the brake light to work too...
 

kuksul08

Suh Dude
I heard my thread got cross posted so I hunted this thread down :D My 85 RZ was non-op'd in 1999 or so, and it cost me $159 for a new plate and to bring it up to current. Couldn't do it online, but the DMV didn't need to see the bike either.

I had the inspection done on my salvage bike a couple years back, at the DMV. All they did was come out and make sure the engine and frame numbers match the papers.
The brake and light inspection can be done at any motorcycle shop and they just make sure your brake light works, headlight, and turn signals. All the safety related stuff. It's not a ride test or anything.

Cool details so far. These old bikes are fun to work on!
 

Slow Goat

Fun Junkie
So far, I'm just around $7.5K............Funny I should spend so much money on a bike that only cost me $400 back in the day

That’s a great part of the story. Money comes and goes but experiences like this one last a lifetime. Or take the better part of a lifetime to finish :rofl

Following with interest.
 
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