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Old 08-15-2012, 11:30 PM   #4816
hughrk
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Location: Scotland
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Quote:
Originally Posted by mr bones View Post
A little info, or a lot would be better.
This bike has no lights, Blinkers or even switches but it seems the wiring harness is still intact. The on-off button works "I've tested, won't start with it unplugged?
The only spare plugs are these two?
Can somebody tell me what they are for?

Thanks mr B
The horn, it mounts on that bracket on the down tube with the bolt in it.
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Old 08-16-2012, 12:39 AM   #4817
mr bones
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Brilliant thanks mate. My cousin is over for a beer. He's a sparky & tested it all for me. "She's got power" just need switch blocks, Blinkers & horn.
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Old 08-19-2012, 07:06 PM   #4818
PCK_4xCustoms
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Soooo hows the tensioner plunger spring supposed to look?

Cause I think mines broke.
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Old 08-20-2012, 03:54 AM   #4819
DrLewall
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Quote:
Originally Posted by PCK_4xCustoms View Post
Soooo hows the tensioner plunger spring supposed to look?

Cause I think mines broke.
uh..it's suppose to look "unbroke"?

got a pic of what yours looks like? The plunger should extend out away from the housing. It is very difficult to push it in with out the use of a small screwdriver. If you can push it in with little effort, then it's broke

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Old 08-20-2012, 07:47 PM   #4820
birds
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A little top-heavy


getting home

Today I "changed" my oil and let my last 2 quarts flow right back out of the drain hole that I forgot to close.
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Old 08-20-2012, 08:10 PM   #4821
PCK_4xCustoms
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Quote:
Originally Posted by DrLewall View Post
uh..it's suppose to look "unbroke"?

got a pic of what yours looks like? The plunger should extend out away from the housing. It is very difficult to push it in with out the use of a small screwdriver. If you can push it in with little effort, then it's broke

The spring i believe is broke. theres a bit wrapped around the shaft inside then more on the OD of the bowl, but not connected
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Old 08-20-2012, 08:31 PM   #4822
bobbed06
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Quote:
Originally Posted by PCK_4xCustoms View Post


Out for a short commute ride around town and I suddenly hear a horrible horrible noise coming from my motor.

Haven't pulled it yet but I'm thinking its cam chain or valve train. I used to have a link to the online clymers but cant find it.

The noise seems to come from the very top by the camshafts.

There was no change in performance, ie. no power loss, popping or the like. Just awful noise.

Any thoughts before I go tearing it apart?
Do yourself a favor and install a 2002 CRF450 timing chain and new tensioner shoes while you are at it. If cash isnt an issue a Hotcam stage 1 and a high comp Wiseco 11:1 piston never hurt anything either.
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Old 08-20-2012, 09:08 PM   #4823
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Quote:
Originally Posted by bobbed06 View Post
If cash isnt an issue a Hotcam stage 1 and a high comp Wiseco 11:1 piston never hurt anything either.

Except engine longevity...
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Old 08-20-2012, 09:13 PM   #4824
bobbed06
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Except engine longevity...
I ran a high comp 426 setup for 2 years solid absolutely no issues whatsoever, but if thats what you wanna beleive than thats fine.
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Old 08-20-2012, 09:38 PM   #4825
KTMSER
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I finished up my DC conversion and lighting and have some left overs you guys maybe interested in...

http://advrider.com/forums/showthread.php?t=817961
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Old 08-20-2012, 10:05 PM   #4826
Dexter2811
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Quote:
Originally Posted by Wallrat View Post
Except engine longevity...
I'm running a 440cc 10:1 comp with Stage II cams since last year and 25000 Kms on it. Using Regular gas (95 RON) and not a single issue.
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Old 08-21-2012, 06:25 AM   #4827
DrLewall
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Quote:
Originally Posted by PCK_4xCustoms View Post
The spring i believe is broke. theres a bit wrapped around the shaft inside then more on the OD of the bowl, but not connected
it does happen..I was abt 40 miles from home when mine went..super easy fix, as long as you can get the tensioner...my last one lasted abt 10 yrs tho, so that is good!
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Old 08-21-2012, 07:07 AM   #4828
curlysurfer
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So your on a limited budget ie one that can't support thousands going out the door each week, what's your order of importance for making the old XR better. for enduro to dual sport type.

In no particular order, but I think I'd rather have the bike handle right before I make it go like stink

USD Forks or brace, and spring/revalve stock fork
rear shock rebuild and setup for my fat arse
pumper carb
cams
stroker crank
stator
headlight
crf450

lets hear what you think
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Old 08-21-2012, 08:25 PM   #4829
PCK_4xCustoms
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Quote:
Originally Posted by DrLewall View Post
it does happen..I was abt 40 miles from home when mine went..super easy fix, as long as you can get the tensioner...my last one lasted abt 10 yrs tho, so that is good!

Yeah, ordered one from bike bandit, managed to fat-finger the order and got the '' cam chain tensioner'' and not the ''plunger tensioner'' which is what I need.... nearly $30 in shipping later..... I have the right item on the way. I was considering the manual adjuster, but figured OEM in this case was the best bet.
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Old 08-21-2012, 11:36 PM   #4830
Wallrat
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Quote:
Originally Posted by bobbed06 View Post
I ran a high comp 426 setup for 2 years solid absolutely no issues whatsoever, but if thats what you wanna beleive than thats fine.
Quote:
Originally Posted by Dexter2811 View Post
I'm running a 440cc 10:1 comp with Stage II cams since last year and 25000 Kms on it. Using Regular gas (95 RON) and not a single issue.

Any reputable builder will agree that raising the compression is the best way to shorten the life expectancy of the engine. I'm not saying your engine will blow within ____ years, I'm just saying that the XR400 is renowned for its reliability. That's its major selling point! Sure you can build the crap out of it, trash the reliability, but in the end you'll have an engine with power comparable to a stock CRF450. Better IMO to play to the natural strengths and weaknesses of a given machine, and stop trying to figure out how to turn a pickup truck into an indy car.
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