The XR400 Thread

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

  1. Stretch67

    Stretch67 Mad Scientist

    Joined:
    Mar 22, 2006
    Oddometer:
    7,278
    Location:
    Bent, But Not Broken
    I performed a pretty thorough once-over on mine since bringing it home earlier last month. It had started and run just fine, with no smoke, but the clutch was kind of grabby, and there was a hell of a racket coming from the valve cover. The valves were in spec, and the engine had great compression against the kick-starter, so I was pretty confident I had a good foundation to work with. It had started on the first kick, so I knew she liked me and wanted me to take her home. So I did.

    And...

    • New wheel bearings (double-sealed bearings, re-packed with waterproof grease and re-sealed. I would seriously recommend this. New bearings frequently have a ridiculously small amount of grease in them from the factory).
    • New chain & sprockets
    • Re-machined & shimmed brake pedal, described earlier here.
    • Re-welded cracked shift lever
    • New brake pads, cleaned / polished pins
    • Cleaned & lubed odometer drive
    • Flushed & replaced brake fluid, Dot 4
    • Waterproof grease on all rear suspension pivots & links and reassemble.
    • Soaked carb in Pine-Sol for a couple days, then careful cleaning & reassembly. 60 / 158 jetting, fuel screw 2 turns out.
    • Home-built extended idle screw.
    • Clutch basket fingers filed smooth, new cable.
    • Cleaned both oil strainers. Photo of sump strainer posted here earlier.
    • 2002 CRF450 cam chain, tensioner plunger OK.
    • Removed non-functioning auto-decomp assembly from cam, welded those two oil holes shut in cam.
    • New rockers, adjusted valves.
    • Removed & cleaned airbox & drains
    • Gordon's Mods (Uni filter, no snorkel, ground header welds). Stock muffler though. I like quiet bikes.
    • Wrapped header & sealed w/ high-temp paint.
    • Threads of all removed bolts were cleaned on buffer w/ wire wheel...
    • Every bolt going into steel was greased
    • Every bolt going into aluminum or high-temp application was Never-Siezed.
    • New grips & handguards
    • New footpegs ($20 eBay big 'uns)
    • Clean & flush tank
    • New fuel line & inline filter
    • Denso Iridium plug
    • Plug cap resistor replaced with copper rod
    • New fenders (red Acerbis)
    • Straightened bent subframe. Item had already been reinforced at the usual break point.
    • Rotella T6 5W/40
    • Fresh 93 octane


    And...



    [​IMG]

    IT... IS... ALIVE!!!

    Baby started on the FIRST KICK! :clap

    Nice and smooth, with no racket at all coming from the valve cover... just a nice sexy whir.

    A ride around the neighborhood (in the dark, lights work) revealed no nasty surprises. Clutch friction was good at low speed top-gear roll-on, no slipping. Great low-end torque, smooth power delivery with no obvious off-idle dead spot.

    SO HAPPEE!
  2. G600

    G600 Been here awhile

    Joined:
    May 18, 2009
    Oddometer:
    466
    Location:
    Iceland
    Nice :clap:clap Congrats. Quite a lot of work....
  3. franga

    franga Adventurer

    Joined:
    Oct 19, 2012
    Oddometer:
    16
    Hey guys,

    lovin this forum. ive got a 140/80/18 rear tire and it needs changing. will a 130 90 18 fit?
    cheers
  4. DrLewall

    DrLewall The Human GPS

    Joined:
    Aug 20, 2008
    Oddometer:
    35,573
    Location:
    Drakes Creek, AR
    nope..too wide 120 90 will fit tho..at least on a 96 model that is
  5. franga

    franga Adventurer

    Joined:
    Oct 19, 2012
    Oddometer:
    16
    cheers for the quicky.

    what sort tires do you guys recommen? 70% dirt riding 30% pavement.
    i wanted to put d606 on the rear and d908 on front but apparently the 606 wont fit...

    front 90 90 21
    rear 140 80 18
  6. DrLewall

    DrLewall The Human GPS

    Joined:
    Aug 20, 2008
    Oddometer:
    35,573
    Location:
    Drakes Creek, AR
    you are talking abt the XR400, correct? mine is a 96 XR4 and I run the D606, 120 90 18 and I can squeeze abt 3000 miles out of it before mounting a new one..wonder why a D606 won't fit on your bike? :scratch
  7. Brewster

    Brewster Adventurer

    Joined:
    Apr 16, 2011
    Oddometer:
    43
    Location:
    Arizona
    [​IMG]

    Sweet !
  8. stteve

    stteve Been here awhile

    Joined:
    Mar 18, 2005
    Oddometer:
    371
    Location:
    Below sealevel
    There is An XR400 in this years Dakar, no 127
  9. Rman237

    Rman237 Ride Rural Texas

    Joined:
    Apr 30, 2007
    Oddometer:
    802
    Location:
    Fayette Co,Texas.
    Says who?? Got a 130/90-18 606 on mine with room to spare. :brow
  10. Rman237

    Rman237 Ride Rural Texas

    Joined:
    Apr 30, 2007
    Oddometer:
    802
    Location:
    Fayette Co,Texas.
  11. MartiniUp

    MartiniUp Long timer

    Joined:
    Jul 14, 2010
    Oddometer:
    2,059
    Location:
    TX
    Very, very nice bike. But I don't see that license plate lasting very long.
  12. Brewster

    Brewster Adventurer

    Joined:
    Apr 16, 2011
    Oddometer:
    43
    Location:
    Arizona

    Thanks for the compliment. The bike gets ridden alot and gets equal TLC. The plate has been on for a couple years now and its never even loosened up (LocTite). The plate bracket is from Scotts Performance ..... my buddy has one on his WR450F and his has not been a problem either.

    Cheers,
  13. RideFreak

    RideFreak Torque Junkie

    Joined:
    Apr 17, 2009
    Oddometer:
    6,677
    Location:
    Out in the NM Dez somewhere
    I did the revalve of the XR4's forks yesterday, threw in some .43kg eibach springs and new seals while I was in there. Pretty easy mod, it took about an hour on the first leg and about 30min on the second. I was able to do it w/o any special tools. I did need to use a airwrench to remove the compression stack out of the bottom since I didn't have the special tool to hold the dampening rod, I also made a seal driver out of 1.25" PVC coupler. Cost: about $135 including oil, sure beats the $300~400 that a suspension tuner would charge.

    I haven't ridden it yet but they feel good, thanks trailryder42!

    Here's the procedure if anyone is interested.
  14. Wilson9068

    Wilson9068 Adventurer

    Joined:
    Jun 3, 2009
    Oddometer:
    63
    Location:
    Colchester, Essex, England
  15. MartiniUp

    MartiniUp Long timer

    Joined:
    Jul 14, 2010
    Oddometer:
    2,059
    Location:
    TX
    The Scotts that has the dampers? Thank you.
  16. Brewster

    Brewster Adventurer

    Joined:
    Apr 16, 2011
    Oddometer:
    43
    Location:
    Arizona
    That is correct, if the web-site says they don't have it, I'd call them anyway. I went to buy one for my Son's bike and it was in stock although the web-site said they were out.

    Cheers,
  17. Czechsix

    Czechsix Slower than you....

    Joined:
    Sep 7, 2008
    Oddometer:
    316
    Location:
    SoCal San Diego Suckage
    Should fit fine, I'm running a 130/90-18 D606 on mine.
  18. Czechsix

    Czechsix Slower than you....

    Joined:
    Sep 7, 2008
    Oddometer:
    316
    Location:
    SoCal San Diego Suckage
    Go Boyer!

    From google translate and the Dakar site:

    "bike only costs 3500 euros! '
    This time comeback for Nicolas Boyer. He loves the bike in all its forms, and practice since the age of seven years on the tracks cross or enduro, the most prestigious circuits as the Bol d'Or, and of course on the dunes of Dakar, he won in 2001, finishing 35th on the same shores of Lac Rose. Since the Ard├Ęche also tasted the boat races, but returned after a 12 year absence on the gold standard, the Dakar. To spice up the game, Nicolas is not only committed without assistance, but especially straddles an old Honda XR 400 from 1999, a model that will only drive the rally. With one of the smallest budgets of the plateau, the ghost also wants to show that the Dakar can be considered modestly.

    "The same year, I had the Dakar and the Bol d'Or, which is not bad for a biker. Since then I've done other things, but every time I meet someone, he asks me when I'm leaving on the Dakar. And this year, I got the call from South America. I have an old bike, but it is a simple and reliable mechanics. There is a sentimental side to jump with a motorcycle in 1999, but it also worked many times. When others leave with a machine 35 000 euros, mine only costs 3500 euros! I have a total budget of 25,000 euros, I do not see how we can do less. I'm trunk-bikes because I think that is where are the true values ​​of Dakar. Moreover, if the objective is simply to reach the end, I'm also tempted by the victory in this category. "
  19. Wilson9068

    Wilson9068 Adventurer

    Joined:
    Jun 3, 2009
    Oddometer:
    63
    Location:
    Colchester, Essex, England
    Finished in 107th of 169 riders, under an hour behind Depres!
  20. Czechsix

    Czechsix Slower than you....

    Joined:
    Sep 7, 2008
    Oddometer:
    316
    Location:
    SoCal San Diego Suckage
    :cry

    Dammit. I really didn't want to split the case.

    Damn.