The XR400 Thread

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

  1. Ed@Ford

    Ed@Ford Long timer

    Joined:
    Jan 16, 2004
    Oddometer:
    1,699
    Location:
    Dearborn MI
    Sooo...just one more time...the piece that holds the shim stack that needs modifying as described in TrailRyder 42's write up is "(18) Center Bolt" on page 13-14 0f the XR400 Service manual...right?

    Thanks, Ed
  2. G600

    G600 Been here awhile

    Joined:
    May 18, 2009
    Oddometer:
    464
    Location:
    Iceland
    Yes.
  3. franga

    franga Adventurer

    Joined:
    Oct 19, 2012
    Oddometer:
    16
    bad news - still having problem with loosing oil. im gonna do a compression test this week. hope it sheds some light on it.
    good news - ive got my new d908's and cant wait to try them out!
  4. RideFreak

    RideFreak Torque Junkie

    Joined:
    Apr 17, 2009
    Oddometer:
    6,544
    Location:
    Out in the NM Dez somewhere
    The shim stack is included in the piece that threads out of the bottom of the fork when you are disassembling them. It's very easy to do.


    BTW, I'm going to be selling the XR4 pretty soon if you guys know anyone looking for a nice tagged XR4, let me know. This was going to be my primary DS bike so I didn't skimp on it. I came across a 525 that I've been looking for so I need the room.

    It started like as a 97, orig owner put on one of those cool tool boxes that goes under the LH numberplate. I got it after the bike had been sitting for years.
    [​IMG]

    Here's a list of what's been done.
    New Plastic, front & rear fenders and BD headlight shell.
    4 Gal Clarke Tank
    Renthol Bars with risers
    Small rear rack
    New skidplate
    New handshields
    Cool Alum enduro tool box under LH number plate.
    Devol Frame guards
    XR650R Clutch/Decomp lever assy
    Rear alum sharkfin
    Nicely done DS electrical sys with a RS 200W stator. HD VR/Rec w/ Cap, This was setup as an AC/DC configuration, 100W DC runs the Fr & Rear brake lights, horn, 55/60W BD headlight and LED taillight, hi/low/off/horn switch. 100W of AC is still avalable or it can easily be reconfigured into a single 200W system. Included DC outputs under the seat and tank for GPS power etc...

    Did a full rebuild on the forks, .43Kg Eibach Springs (180lb rider) added new seals, scrapers, and it has recent OE fork covers.

    Pulled the spring on the rear and checked dampening, it was fine, reassembled and set the sag.

    Added a BD Analog speedo

    It's got D606s fr & rear (about 75% left)

    Recent chain & sprockets, includes 16T highway sprocket

    Motor: New Piston, rings & VG seals. I originally tore this down to replace the aged VG seals, fully intended on replacing the cam chain and boring it at the same time. When I got it apart it was one of the cleanest motors I've ever disassembled and I've done more than my share. Zero wear in the cam jouranals, cam lobes and rockers looked like new, after seeing the inside I know this was a very low mile motor. Cyl still had the entire crosshatch. I replaced the piston and rings anyway and put in some viton seals, left it stock. While I was in the motor I checked the clutch plate thickness figuring it might need a clutch, like the rest of the motor it was fine.

    Completly cleaned and greased the suspension linkage and swingarm bolt. This bike is from a dry climate so it saw very little water, swingarm bolt came right out which tells you something.

    Had that typical XR400 crack in the subframe crossmember under the seat so it got gusseted and rewelded.

    Installed a dual taper needle in the carb, checked flot drop & height, rejetted for current alt. Includes jets :D

    Had the sidecovers powdercoated and highlighted the Honda lettering to give it a little bling.

    The rims are straight and not scratched up.

    Here's some pics:

    This one shows the toolbox.
    [​IMG]

    Electrical System - the rest of the connections are under the tank and out of the way.
    [​IMG]

    Bright Light
    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    The good: everything :D

    The bad:
    Cap didn't work out so well, system works fine but at idle there is a slight dimming of the headlight (no prob, it's still very bright) but it wants to be revved up a little for the horn to work, if the lights are turned off it works fine. It'd be super easy to swap in a small ni-cad batt pack and locate it where the cap is currently located. I had this same setup on my XR650R with a small battery and the systems charges it easily.

    Front brake light switch is inop, I have another to switch it with.
  5. KilLeR Kawasaki

    KilLeR Kawasaki Marky A

    Joined:
    Jun 1, 2008
    Oddometer:
    968
    Location:
    Littleton, Colorado
    Chris, your video reports are great. You and your buddies really know how to ride. How much for your XR400? BTW, where do you get the downspout for the stock exhaust?
  6. RideFreak

    RideFreak Torque Junkie

    Joined:
    Apr 17, 2009
    Oddometer:
    6,544
    Location:
    Out in the NM Dez somewhere
    Thanks, the orig owner was a good rider that kept this thing nice, not sure where he picked it up, it's cool though.

    PM'd you with the price, don't want to get in trouble :D
  7. tjrockit

    tjrockit One day closer...

    Joined:
    Nov 11, 2008
    Oddometer:
    1,214
    Location:
    Austin, TX
    Because the XR400R and XR250R have the exact same part number for the clutch and decompression lever, I wanted to ask this question on this thread as well.

    I got my CRF450R Clutch/Hot Start perch. After looking it over, I've learned that the cable ends are not interchangeable. I called Motion Pro and I can get 2 custom cables made for $75 + shipping. Before I go that route I wanted to ask the collective if anyone has tried the XR650R Clutch/Hot Start perch and if it worked with the stock OEM XR400R cables with no additional modifications. :ear

    XR650R Perch
    [​IMG]
  8. DrLewall

    DrLewall The Human GPS

    Joined:
    Aug 20, 2008
    Oddometer:
    34,674
    Location:
    Drakes Creek, AR
    :y0!

    the 650 perch works good on my lil xr4 :D plug-n-play it was for me..
  9. RideFreak

    RideFreak Torque Junkie

    Joined:
    Apr 17, 2009
    Oddometer:
    6,544
    Location:
    Out in the NM Dez somewhere
    My XR4 comp cable was slightly larger in diameter than the hole in the perch, I just drilled it out since there's no adjuster. It was almost plug n play for me. Def liked the way it cleans up the bars.
  10. stteve

    stteve Been here awhile

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    Mar 18, 2005
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    371
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    Below sealevel
  11. AZ Mark

    AZ Mark Been here awhile

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    Oct 13, 2011
    Oddometer:
    893
    Location:
    Wickenburg AZ
    Inmates....



    I have a Seat Concepts seat listed in the Flea Market under Parts.

    A great improvement over the stock seat ! ! !
  12. Rman237

    Rman237 Ride Rural Texas

    Joined:
    Apr 30, 2007
    Oddometer:
    802
    Location:
    Fayette Co,Texas.
  13. RideFreak

    RideFreak Torque Junkie

    Joined:
    Apr 17, 2009
    Oddometer:
    6,544
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    Out in the NM Dez somewhere
    If I had saw that 2 weeks ago I'd be all over it, good deal! Looks like the XR4 might be sold so I done with the mods.
  14. MartiniUp

    MartiniUp Long timer

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    Jul 14, 2010
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    2,008
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    TX
    Wherever it is it is hidden well!
  15. tonusmaximus

    tonusmaximus maximus

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    Jun 18, 2011
    Oddometer:
    591
    Location:
    nky
    i found it by looking at his posts.

    Sent from my SPH-D700 using Tapatalk 2
  16. RideFreak

    RideFreak Torque Junkie

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    here
  17. krebsatm02

    krebsatm02 Adventurer

    Joined:
    Nov 30, 2009
    Oddometer:
    20
    Location:
    Bryan, TX
    Is there a collection of front racks on here? I'm wanting to build a new rack with a 7" round light and also integrate the fuse/dual sport crap, gps mount, etc... and I'm looking for ideas.

    Here is one I made in a hurry a few years ago before our CDR trip.[​IMG]
  18. hughrk

    hughrk Adventurer

    Joined:
    Jul 18, 2011
    Oddometer:
    75
    Location:
    Scotland
    You havent read the other 5437 posts????????:deal

    P.S. Not something I remember seeing!
  19. Stretch67

    Stretch67 Mad Scientist

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    Mar 22, 2006
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    7,049
    Location:
    Bent, But Not Broken
    Me neither, and I've been through this whole thread twice in the past month.

    Krebs, click here and scroll down to 'Panniers & Racks', and jot down the post numbers listed. Then sift through those posts here on the XR4 Thread.

    But like Hughrk said, I don't recall seeing any. Good luck.
  20. PCK_4xCustoms

    PCK_4xCustoms lost

    Joined:
    Apr 25, 2010
    Oddometer:
    269
    Location:
    Back in the city :( Livonia MI
    anybody put a yam carb onto the xr4? came off a 04 yz250f