The XR400 Thread

Discussion in 'Thumpers' started by Hayduke, Jan 16, 2008.

  1. gordo5

    gordo5 Roadkill

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    538
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    Toronto, Ontario
    Not to mention the USD forks :evil
    #21
  2. oziexplorer

    oziexplorer fugarewe tribe member

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    Perth, West Oz
    I sold my KTM400 to buy the last brand new one available in Perth, Australia; mainly because I was working overseas at the time and wanted something the could sit in the shed for two months or more and be rolled out, kicked in the guts and trail-ridden without any dramas.
    Going from a KTM back to a XR400 was....interesting, so I've been busy trying to improve the XR400 whilst retaining it's engine reliability.
    So - I haven't touched the engine apart from the Vortex ignition.
    So here's what I've done to it:
    De-restricted
    Barkbusters
    Pro Taper bars
    Riser kit
    Acerbis headlight
    B&B Bashplate
    IMS Stainless Steel Pegs (pivot pegz soon to be available :clap)
    Scotts Steering Damper with BRP submount kit
    IMS Gearshift lever
    B&B Rear disc guard
    Eibach Fork Springs
    Eibach Rear spring
    Onlins rear shock & spring (not yet fitted)
    Trailtech Vapor computer
    ASV unbreakable levers
    Pro-Grip Grips
    Unifilter Airfilter
    Works Connection frame guards
    Wave Front Disc
    Chain Gang rear sprocket (approx 10,000mi lifespan)
    B&B exhaust baffle
    Goodridge front brake line
    Acerbis long range tank (for the desert trips in outback Australia http://www.advrider.com/forums/showthread.php?t=169841)

    [​IMG]
    [​IMG]
    [​IMG]
    close up of the damper and speedo
    [​IMG]

    with Acerbis 22L long range tank (16km/L economy offroad giving about 350km, or 218mi)
    [​IMG]
    [​IMG]
    [​IMG]

    here's recent pic with the new Acerbis Cyclops headlight

    [​IMG]

    In case you're wondering, the camping gear in the grey bag is all lightweight stuff; the bag weighes under 5kg; I carry/wear a backpack as well.
    [​IMG]

    I may look into a set of dirtbagz for it......but now I've got the HP2 for longer range touring with more plush luggage capability :evil

    I really enjoy the XR400...they're a fantastic all-rounder; and were a good competitor to the DRZ400 (which now has no competitor in this class)

    Thanks for creating the thread.
    #22
  3. Hayduke

    Hayduke ///SAFETY THIRD/// Super Moderator

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    NICE! I have a 950 Adventure for really long range with lots of luggage capacity, but where I live I can easily ride further than the stock tank will allow before finding fuel. How do you like the Acerbis tank? Can you actually use all the fuel, or does some get trapped in the low front "wings"?
    #23
  4. oziexplorer

    oziexplorer fugarewe tribe member

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    Thanks.
    I have run dry before; so yes, all of the fuel is usable with the acerbis tank.
    The tank is also used on the XR600/XR250 - I bought my red ones (older) off ebay. You just need different mounting brackets.
    The white tanks can mark easily with rub marks - especially if you ride in red clay in the rain...
    You get used to the tank's design pretty quickly, and when you put the original one back on; the XR400 feels like a 125..:)
    #24
  5. Logan Black

    Logan Black Team Bacon

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    Nah it aint a huge problem just takes some practice and technique.


    I love me XR:clap
    #25
  6. Hayduke

    Hayduke ///SAFETY THIRD/// Super Moderator

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    I can see that it'll take some practice. This is the first kick start bike I've had. Well, since I was 13 or so. I'm getting it. Still don't know what the hell that extra lever is for though. :lol3
    #26
  7. Eurobiker

    Eurobiker Vintage Cat Herder

    Joined:
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    Oddometer:
    6,051
    Location:
    Albuquerque, NM
    Here, my kicker N00b..... from our friends at 4Strokes.com. Pay particular attention to "DON'T TOUCH THAT THROTTLE!"

    General Four-Stroke Starting Procedures
    • If the engine is cold, it may help to turn up the idle screw slightly to aid in warm-up and give the engine a little extra fuel.
    • Turn the choke to full on.
    • Pull in the compression release lever, if so equipped, and push the kick-starter through 3 or 4 times. This will prime the engine with fuel.
    • Without the compression release lever pulled in, slowly push the kick-starter around to get the piston to top dead center. You'll know this when the kick-starter becomes hard to push down (indicating compression stroke).
    • Allow the kick-starter to return to the top.
    • Pull the compression release lever in and push the kick-starter down just a little (around an inch and a half or two). This gets the piston just past top dead center.
    • Let the compression release lever back out and bring the kick-starter back up to the top.
    • Now push the kick-starter down with as much force as you can and it should fire up. If it doesn't, wait a few seconds and try the procedure again.
    Honda XR650R - Ken A. Moore Cold engine (cool outside)
    • Do not twist the throttle, no matter what you think or feel, or you will flood it.
    • Choke full on, ignition off.
    • Pull in compression release and kick the engine 4 kicks. This primes the engine.
    • Ignition switch on, choke on. Slowly kick the engine until TDC (the hard spot), then stop.
    • Pull in the compression release and gently push the kick leaver so the engine is just past TDC, then stop. Release the compression release leaver.
    • Now give her a nice firm kick of the kick starter. DON'T TOUCH THAT THROTTLE! She should fire up. If not, go back to #4.
    • Move choke to 1/2 position. DON'T TOUCH THAT THROTTLE!
    • After about 60 seconds turn off the choke. DON'T TOUCH THAT THROTTLE!
    • After about 2 minutes and the engine is getting warm, you may now slowly twist the throttle but go easy until fully warmed up.
    #27
  8. Hayduke

    Hayduke ///SAFETY THIRD/// Super Moderator

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    Thanks Mark!

    Wow! I was doing it right after all??!!! It does make sense, doesn't it?

    Oziexplorer: Nice ride report on the Golden Quest Trail.:thumb Glad to see this bike is suitable for some longer rides!
    #28
  9. oziexplorer

    oziexplorer fugarewe tribe member

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    cheers mate.
    a pair of earplugs makes the long rides much more enjoyable.
    #29
  10. 1stworks

    1stworks dude

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    #30
  11. Oni

    Oni Ronin

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    Location:
    Pasadena - Californistan
    2002 here.

    IMS 4 gallon tank
    IMS pro footpeg
    GPR stabilizer
    FMF Fat bars
    Baja Designs DS kit
    Skid plate
    Gordon mods
    .41 fork springs
    #31
  12. Hayduke

    Hayduke ///SAFETY THIRD/// Super Moderator

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    Looks like you've tried various headlights. How do you compare them- Hows the HID? :tb
    #32
  13. 1stworks

    1stworks dude

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    The hid is really bright but too bright for street.
    Even w/aimed down i still get flashed.:cry
    I would like to sell hid and get different one.
    There is cool trail tech i think would be perfect.:deal
    The light i have runs w/ out bike running
    witch is cool.


    firstworks
    #33
  14. Hayduke

    Hayduke ///SAFETY THIRD/// Super Moderator

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    Thanks. I may look at a Baja Designs 8" Halogen in the future. Anyone know if the XR400 puts out enough juice to run it?
    #34
  15. TonyDanger

    TonyDanger Adventurer

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    Jan 11, 2008
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    Location:
    Edmonds WA
    I don't think it does. I haven't put one on my bike, but I know a lot of guys that have had to put new high outout stators on to keep up the juice. New stator is $150 from xrsonly.com and are pretty powerful (200w).
    #35
  16. eakins

    eakins Butler Maps

    Joined:
    May 29, 2002
    Oddometer:
    21,612
    Location:
    Fort Collins, Colorado
    great bike for colorado!

    about all it will muster is a 55w up front in stock form.
    baja designs stocks the glass upgrade light housing and you buy a 55w h3 locally. it's enough light to get home if you're late.

    using a 14th fr sproket (with stock rear) is the key colo mountain gearing.

    i'm minimally street legal:
    i wired a hydro brake light switch to the front banjo bolt and then the rear brake assy and soldered in the extra wire (stocked used 2 but it's ready for a 1157 3 wire setup). i use a 1157 heavy duty rear bulb.

    i also use a scotts liscense plate bracket http://www.fourstrokesonly.com/LicensePlateHolder.html (one of the worst designed web pages in existence) with larger washers & then rubber washers on each side of the plate as vibration damping. using small nuts and bolts and your plate will vibrate in pieces.

    i use a ufo fold-in mirror with the 3 nut and bolt tightening hardware at the knuckle. the acerbis fold-in mirror tightens with 3 screws into plastic at the knuckel area and and strips over time.

    that's all that i have for street legal. at dmv, i signed that i have a horn and signals are not needed in colo. no issues with moab cops either. they just want to see an up to date plate. dmv required the bill of sale to state the bike if "for off-road only" then they checked the vin# there, had me sign a form stating it meets the requirements and issued me a tag and title.

    as for the bike TT is the place for tech:
    http://www.thumpertalk.com/forum/forumdisplay.php?f=26
    i've done gordon mods (you've got a nice aftermarket muffler), uni filter/cage upgrade, denso irdium plug, spark plug boot mod http://www.kamware.com/vtr1000f/resistor1.htm and set the valves spot on so it starts easy. i point a small space heater at the motor when it has sat for a few weeks to help it fire.

    just as a repeat:
    mine fires in 1 kick with this procedure:

    turn up idle screw about 1 turn
    full choke
    Pull in decompressor lever & clutch/depress kill button/throttle wide open
    kick 4-5 times (primes the engine)
    release all except clutch
    find TDC with kick start (it’s when you first feel resistance)
    kick w/ no throttle
    don't touch throttle
    go to middle position on choke & let idle
    after a minute turn off choke and turn down idle

    here's a jetting guide assuming gordons has been done.
    xrs are happy when they're leaner than richer so err on the lean side.
    first # is main, second is pilot jet for. 150/50 works from moab to up high for me.
    0000 ft > 160 / 60
    1600 ft > 158 / 58
    3200 ft > 155 / 55
    5000 ft > 152 / 52
    6500 ft > 150 / 50
    9800 ft > 148 / 48

    make sure to check & lube the swing arm bolt asap!!!
    that's the only real issue with an xr4.

    i'd love come down your way sometime and do some trail riding. i have good friends who live in salida.
    #36
  17. Hayduke

    Hayduke ///SAFETY THIRD/// Super Moderator

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    That would be great! Lot's of great riding around here, and with this bike, I'm about to find more!

    Thanks for the info, too. My bike is already plated, but it has nothing but the mirror and brake light, with a plate bolted on the fender. I'm not too concerned about the light, as I don't ride in the dark usually, but it'd be nice to have a bit more just in case. Fuel range could be an issue, so a big tank may be the first mod.... Oh ,yeah, and good pegs and bar risers.


    Let me know if you want to explore around here this summer.

    BTW- got any pics? :D
    #37
  18. eakins

    eakins Butler Maps

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    clark translucent 3.8 gallon tank is the way to go:
    http://www.justgastanks.com/store/index.php?main_page=index&cPath=1_9_123
    fit and finish alot better than IMS 4 gallon tank.

    http://www.rockymountainatv.com/pro...&webTypeId=241&webCatId=12&prodFamilyId=12976

    http://www.rockymountainatv.com/pro...&webTypeId=266&webCatId=12&prodFamilyId=15852

    http://www.rockymountainatv.com/pro...s&webCatId=19&prodFamilyId=8650#vehicleSelect

    replace the rear disc guard with something better.

    do not upgrade flexy oem shift lever! shift shaft is small so a stiffer aftermarket shift lever has snapped a few shafts over the years. not good.
    the stock one can easily be bent back time and time again.

    i'll take you up on that offer.
    #38
  19. Hayduke

    Hayduke ///SAFETY THIRD/// Super Moderator

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    What kind of range do you get with that tank?
    #39
  20. 1stworks

    1stworks dude

    Joined:
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    south side

    I get 200 miles out of mine.



    firstworks
    #40