This is going to be a back burner project as this has never been done before on an XS400. I've decided to try another approach to fitting the charger and this seems to fit (just)

I may get away with a 90mm pulley system which will make the crank fitment a little easier. It will aslo facillitate the jockey wheel and leave enough space for the belt to be pinched. the fuel will enter the top aprt and exit from the bottom Mount/ manifold. not sure whether to have 2 out lets either side (which looks good)or go for a single side to plennum chamber

supercharger mount

A bit more work on mounting the supercharger

checking gaps, belt route, pulley size (prob 60mm 1:1 ratio)

only 50mm gap between the SC and the head, so its an up and over tube arrangment

whilst changing over the fill casting, the last person ommitted to fit a nut on the lobe gears

its a strange size, 14mm x 1mm thread very fine

managed to weld a temporary mount together in steel just to see what fits where etc etc.

think i'm going with 60mm pulleys 1:1 ratio in order for the ribbed belt to follow the starter chain route.

up and over 1.5" tube to the inlets .

there's only 50mm gap between charger and cyl block, so inlet will start off going down into the starter motor area and up to the right side

whilst changing over the oil fill casting, I noticed a nut missing off one of the gears

managed to weld a temporary mount together in steel just to see what fits where etc etc.

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_001_zpslb4mysug.jpg[/IMG]

think i'm going with 60mm pulleys 1:1 ratio in order for the ribbed belt to follow the starter chain route.

up and over 1.5" tube to the inlets .

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_002_zps5fz1jxiv.jpg[/IMG]

there's only 50mm gap between charger and cyl block, so inlet will start off going down into the starter motor area and up to the right side

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_003_zps9culdonn.jpg[/IMG]

whilst changing over the oil fill casting, I noticed a nut missing off one of the gears

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160508_002_zpsjskrllid.jpg[/IMG]

managed to weld a temporary mount together in steel just to see what fits where etc etc.

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_001_zpslb4mysug.jpg[/IMG]

think i'm going with 60mm pulleys 1:1 ratio in order for the ribbed belt to follow the starter chain route.

up and over 1.5" tube to the inlets .

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_002_zps5fz1jxiv.jpg[/IMG]

there's only 50mm gap between charger and cyl block, so inlet will start off going down into the starter motor area and up to the right side

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_003_zps9culdonn.jpg[/IMG]

whilst changing over the oil fill casting, I noticed a nut missing off one of the gears

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160508_002_zpsjskrllid.jpg[/IMG]

managed to weld a temporary mount together in steel just to see what fits where etc etc.

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_001_zpslb4mysug.jpg[/IMG]

think i'm going with 60mm pulleys 1:1 ratio in order for the ribbed belt to follow the starter chain route.

up and over 1.5" tube to the inlets .

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_002_zps5fz1jxiv.jpg[/IMG]

there's only 50mm gap between charger and cyl block, so inlet will start off going down into the starter motor area and up to the right side

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_003_zps9culdonn.jpg[/IMG]

whilst changing over the oil fill casting, I noticed a nut missing off one of the gears

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160508_002_zpsjskrllid.jpg[/IMG]

managed to weld a temporary mount together in steel just to see what fits where etc etc.

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_001_zpslb4mysug.jpg[/IMG]

think i'm going with 60mm pulleys 1:1 ratio in order for the ribbed belt to follow the starter chain route.

up and over 1.5" tube to the inlets .

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_002_zps5fz1jxiv.jpg[/IMG]

there's only 50mm gap between charger and cyl block, so inlet will start off going down into the starter motor area and up to the right side

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_003_zps9culdonn.jpg[/IMG]

whilst changing over the oil fill casting, I noticed a nut missing off one of the gears

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160508_002_zpsjskrllid.jpg[/IMG]

managed to weld a temporary mount together in steel just to see what fits where etc etc.

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_001_zpslb4mysug.jpg[/IMG]

think i'm going with 60mm pulleys 1:1 ratio in order for the ribbed belt to follow the starter chain route.

up and over 1.5" tube to the inlets .

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_002_zps5fz1jxiv.jpg[/IMG]

there's only 50mm gap between charger and cyl block, so inlet will start off going down into the starter motor area and up to the right side

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_003_zps9culdonn.jpg[/IMG]

whilst changing over the oil fill casting, I noticed a nut missing off one of the gears

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160508_002_zpsjskrllid.jpg[/IMG]

managed to weld a temporary mount together in steel just to see what fits where etc etc.

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_001_zpslb4mysug.jpg[/IMG]

think i'm going with 60mm pulleys 1:1 ratio in order for the ribbed belt to follow the starter chain route.

up and over 1.5" tube to the inlets .

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_002_zps5fz1jxiv.jpg[/IMG]

there's only 50mm gap between charger and cyl block, so inlet will start off going down into the starter motor area and up to the right side

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_003_zps9culdonn.jpg[/IMG]

whilst changing over the oil fill casting, I noticed a nut missing off one of the gears

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160508_002_zpsjskrllid.jpg[/IMG]

managed to weld a temporary mount together in steel just to see what fits where etc etc.

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_001_zpslb4mysug.jpg[/IMG]

think i'm going with 60mm pulleys 1:1 ratio in order for the ribbed belt to follow the starter chain route.

up and over 1.5" tube to the inlets .

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_002_zps5fz1jxiv.jpg[/IMG]

there's only 50mm gap between charger and cyl block, so inlet will start off going down into the starter motor area and up to the right side

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160515_003_zps9culdonn.jpg[/IMG]

whilst changing over the oil fill casting, I noticed a nut missing off one of the gears

[IMG]http://i73.photobucket.com/albums/i231/drewpy_1/tracker/supercharging/WP_20160508_002_zpsjskrllid.jpg[/IMG]

Got the GS500 liners machined today so they will fit into the barrel and case of the bike

new pistons

Decidied that the GPZ900 pistons will have too high a compression so I've done some digging and come up with Honda transalp pistons at 74mm.

just bought  some GS500E cylinder liners and had them machined OD 81mm and will get them fitted to an enlarged cyl and crank mouth.

I have also got  another engine so if it goes pear shaped, I have a back-up

New Con rods and GPZ pistons

Bernd on  xs400.net in Germany have found that XJR1300 conrods fit the XS crank.

He also used GPZ900 standard pistons, whilst  at 72.5mm, still ok to bore out the barrel to that size.

 the bearing shells of the XJR.
XS .............. => XJR
1L9-11656-00 => 36Y-11656-00
1L9-11656-10 => 36Y-11656-10
1L9-11656-20 => 36Y-11656-20
1L9-11656-30 => 36Y-11656-30

The pistons need to be modified on a milling machine and new valve cut outs made for the XS valves

 The only issue is that they are 1mm too high.

SU carb

Today I started collecting parts for the build.

SU 1 1/4" H2 rebuilt

this mounts at an angle which hopefully will pair up with the angle of the charger.

Need to think about pipe work and mounting the blower.

For this I have made some mounting templates out of card and when I get the tracker MOT'd (as its due) and the FZ600 back up and running, I'll take the bike off the road.

supercharging the XS

this arrived today

Its an Aisin AMR300 Supercharger which I'm fitting to the tracker.

Going to take all year to do, but I think it will be awesome

XJR1300 conrods, weld up the oil hole for the starter chain and fit a 4 rib serpentine pulley in place of the original sprocket.

need to work out the ratio (leaning on 1:1)
Its a suck through system so can't have an intercooler, pop off valve needed for backfires

there's one fitted to an SR500 for inspiration