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Old 05-22-2011, 06:53 PM   #3421
grub
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Quote:
Originally Posted by Brewster View Post
NOS 2002 XR400 I picked up a few weeks ago. Just got her plated for dual sport duty.
Nice find, that bike looks like it has never been ridden...
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Old 05-22-2011, 07:04 PM   #3422
Brewster
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Originally Posted by grub View Post
Nice find, that bike looks like it has never been ridden...
It might have an hour or so on it. The engine still smells new when you fire her up. I just got finished uncorking her and got her plated.

She really runs nice.
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Old 05-23-2011, 05:20 AM   #3423
Ed@Ford
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I sure would like to know how you boys find almost new XR400's....my 96 is developing issues.

The swing arm bolt seems to be rusted in place.. The ugly task of repairing has been documented here. Mine is laying on it's left side and I go out and shoot penetrating oil in the pocket where the swing arm nut was....oil seems to disappear quickly....but no puddles anywhere of it coming out. Gonna continue this for a week. (Riding the KLR in the mean time). Maybe hit it with the impact after some more soaking. Soooo...questions are....the swing arm bolt is not threaded into the RH side if the frame...right?...just a slip fit..right? Also, it would seem that if necessary, since the SA bolt is hollow, by drilling successively larger bits, you could drill away both ends of the bolt, and the SA might possibly fall out...right?
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Old 05-23-2011, 06:36 AM   #3424
DrLewall
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SA bolt not threaded into the other side..just a push thru with a nut on the other end..GOOD LUCK! (from someone who knows and has the pix to prove it!)
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Old 05-23-2011, 06:42 AM   #3425
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Originally Posted by DrLewall View Post
SA bolt not threaded into the other side..just a push thru with a nut on the other end..GOOD LUCK! (from someone who knows and has the pix to prove it!)
Thanks...rode over the weekend....there's nothing...in my opinion...out there to replace it with...except another one..and I can always dream about the 440 model with electric start that they actually sell in Italy!!
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Old 05-23-2011, 06:51 AM   #3426
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Would like to join this forum----anyone know where i can find a nice xr4 in the northeast?
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Old 05-23-2011, 06:54 AM   #3427
huckleberry
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Quote:
Originally Posted by Brewster View Post
NOS 2002 XR400 I picked up a few weeks ago. Just got her plated for dual sport duty.
praytell where did you get this and can i get 1?
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Old 05-23-2011, 10:38 AM   #3428
Luke
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Quote:
Originally Posted by Ed@Ford View Post
.... Maybe hit it with the impact after some more soaking. Soooo...questions are....the swing arm bolt is not threaded into the RH side if the frame...right?...just a slip fit..right? Also, it would seem that if necessary, since the SA bolt is hollow, by drilling successively larger bits, you could drill away both ends of the bolt, and the SA might possibly fall out...right?

I assume you mean an impact wrench? That won't help much as the main culprits are the swingarm bearings. When you turn the bolt they will just turn freely with it. Turning the bolt does help free it from the engine cases.

Impact -in the form of a big hammer- is your best starting point.

To drill it out you will need to go in around 3 inches on either side to get past the swingarm bearings.
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Old 05-23-2011, 11:15 AM   #3429
Gap-year-trip-2010
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New entry!!!!

Ive just got an XR400!!! Yay.

2003 Crf250f Front end.
Improved rear fender.
Mikuni 42mm Carb (awesome!)
Michelin T63's (front is sh... off the road)

XR400

rear side.

DSCF5711

Hope the thread entry works.
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Old 05-23-2011, 01:46 PM   #3430
laramie LC4
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Ok, who's got the skinny on how to upgrade the ol' xr400r to USD forks? i know several of you have done it. let's hear the details, or at least a link to somewhere that does.

i want to know...

1) what forks you used
2) triple clamps
3) axle used
4) brake caliper
5) stem bearings used
6) what front wheel

thanks,

laramie
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Old 05-23-2011, 05:56 PM   #3431
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Quote:
Originally Posted by huckleberry View Post
praytell where did you get this and can i get 1?
I bought it locally from a private party in Phoenix. I pretty much watched craigs list and ebay daily looking for a NOS 400. They are out there but you've got to be quick to act.

Keep looking and be patient.

Cheers,
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Old 05-23-2011, 05:58 PM   #3432
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Quote:
Originally Posted by huckleberry View Post
Would like to join this forum----anyone know where i can find a nice xr4 in the northeast?

I have a nice 2001 in the Southwest.

Its in the classifieds over on TT, how about a road trip?
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Old 05-23-2011, 10:02 PM   #3433
Luke
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Quote:
Originally Posted by laramie LC4 View Post
Ok, who's got the skinny on how to upgrade the ol' xr400r to USD forks? i know several of you have done it. let's hear the details, or at least a link to somewhere that does.

i want to know...

1) what forks you used
2) triple clamps
3) axle used
4) brake caliper
5) stem bearings used
6) what front wheel

thanks,

laramie

Mine:



'09 CRF450R front end.

Forks, axle, wheel, brake, triples, stem all from the CRF.

The head bearings and steering stem nuts are XR stock, the stem was machined to fit the XR nuts, but it's length wasn't changed, so the CRF top nut was re-used on the bottom as a spacer.



The castle nut is from the XR, the hex nut is from the CRF.

If I were to do it again I would go with the All-Balls conversion bearings and a spacer.


I had to mill the steering stops off the lower triple clamp to clear the oil cooler and make new ones in the right place for the XR. These were my first attempt. The HDPE wasn't strong enough and I made another set from aluminum.



The XR fender was a direct bolt-on. The brake caliper mounted differently to the fork, so I had to get a new caliper. The hydraulics are identical, the only difference is the carrier bracket. The '02-'07 CRF uses the same caliper bracket as the XR




The steering range sucked because the lower clamp bolts interfere with the gas tank, so I took a heat gun and trailer hitch ball to the tank. It's now almost as good as the stock XR.




In case you need encouragement, I've done most of the big upgrades for my XR and this one was the best.
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Old 05-24-2011, 12:07 AM   #3434
huckleberry
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can someone fill me in on the pumper carb? Is it really that much better than the stocker?
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Old 05-24-2011, 09:30 AM   #3435
Luke
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Originally Posted by huckleberry View Post
can someone fill me in on the pumper carb? Is it really that much better than the stocker?
I thought the improvement was modest. The difference between a properly jetted stock carb and the mikuni pumper was much less than the difference between stock jetting and correct jetting on the stocker.
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