The XR400 Thread

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

  1. mvg2

    mvg2 Been here awhile

    Joined:
    Jul 1, 2007
    Oddometer:
    175
    Location:
    Pittsburgh, PA
    Success!! :D


    [​IMG]

    You got a tool for everything over there don't you? :) thanks for the offer, but I got 'em apart. I was just being a big puss and a bonehead. Together, not a good recipe for success.

    Ordered the countershaft and the crf cam chain from bike bandit. Hope they gather that shit up quick and get it to my door!
  2. TheHoff

    TheHoff Don't Hassle Him

    Joined:
    May 1, 2010
    Oddometer:
    39
    Location:
    Helena, MT
    I have a line on an inexpensive used Revloc, but the owner says it may need new clutch plates soon. It's not the Dyna ring style- it's the replacement basket + pressure plate system. After researching I can't find any info on replacing the wear parts.

    Does anyone know if the older style Revlocs used stock clutch parts?

    Given that Revloc is now out of business I don't want to buy something I can't get replacement wear parts for...

    Thanks!
  3. wvridgerider

    wvridgerider Been here awhile

    Joined:
    Jan 7, 2009
    Oddometer:
    585
    Location:
    west virginia
    How does everything else look? I hope all goes well for you, that is a pretty big stator.
  4. mvg2

    mvg2 Been here awhile

    Joined:
    Jul 1, 2007
    Oddometer:
    175
    Location:
    Pittsburgh, PA
    Mostly all good. Just some trace pieces of ferrous metal in the case from the aftermath of the countershaft snapping.
    Funny you brought the stator up. a couple of the coils actually look like they cooked? Carbon caked. Can't say I've ever seen that before
  5. tjrockit

    tjrockit One day closer...

    Joined:
    Nov 11, 2008
    Oddometer:
    1,214
    Location:
    Austin, TX
    Since the XR400R and XR250R are similar, I thought I'd post this info here as well.

    Since I own a XR650L, I've noticed that there are several parts that are interchangeable or there are a few parts that are different but overall it's the same thing.

    The Clarke tank for the XR650L/XR600 can be mounted to the XR250R but you need different brackets and a petcock for a XR650L/XR600. Same is true for the Acerbis tank.

    Here is my install.

    Custom fabbed brackets, uses the OEM rubber grommet and collar.

    [​IMG]

    [​IMG]

    From the custom bracket I made, the measurements are:

    1) 7.5 cm
    2) 9.5 cm
    3) 4.0 cm

    [​IMG]

    I mounted a large piece of clear plastic on the tank and then marked off where I needed the hole that mounts to the frame. I didn't account for the thickness of the bracket, so my measurements are off just a little but with some wiggling and pressure, I was able to get it to bolt on.

    [​IMG]

    Uses the same seat hook off the 250. I added a small washer under the collar to make it a little easier to get the seat hooked.

    [​IMG]

    Here is a side view after it was mounted with the petcock. I added a fuel filter just to be safe.

    [​IMG]

    [​IMG]

    And there you have it. You can buy a used XR650L/XR600 Clarke tank, fab some mounts, obtain a XR650L/XR600 petcock and away you go.

    As a side note, I was a little bummed when I received the used tank. The PO painted the underside of the tank which I couldn't see in the pics. Oh well, small thing but still works.

    All I need to do now is field test it.
  6. tonusmaximus

    tonusmaximus maximus

    Joined:
    Jun 18, 2011
    Oddometer:
    702
    Location:
    nky
    im also in midst of changing out xr400 to crf450 cam chain. thanks you guys on the buddy holding down the brake deal, etc. I'm almost at that point. Honda Service turned me away on doin it and I'm glad they did since all I need is here. Its times like this its really good to have more bikes and ADV. Cheers.
  7. tonusmaximus

    tonusmaximus maximus

    Joined:
    Jun 18, 2011
    Oddometer:
    702
    Location:
    nky
    anyone know if threads on clutch basket nut are reverse threaded or not? Also the nut holding the crank if that is what it is. The clutch nut is peened on also. I am gonna throw the impact to them but I wanted to make sure I'm not gonna be working against the grain so to speak... Thanks.
  8. Stretch67

    Stretch67 Mad Scientist

    Joined:
    Mar 22, 2006
    Oddometer:
    8,414
    Location:
    Bent, But Not Broken
    Regular thread... righty-tighty, leftie-loosey.
  9. tonusmaximus

    tonusmaximus maximus

    Joined:
    Jun 18, 2011
    Oddometer:
    702
    Location:
    nky
    Thanks stretch. Well the crf450 chain went right on and everything is right as rain again. Bike is all buttoned up and purring. Had a ton of noise before and was surprised the guides looked good.

    Sent from my SPH-D700 using Tapatalk 2
  10. BLZBRKR65

    BLZBRKR65 Been here awhile

    Joined:
    Jan 19, 2010
    Oddometer:
    228
    Location:
    Houston, Tx.
    Is anyone running this setup on their XR400? I have an IMS 4.0 gal tank and in the process of putting some Showa USD forks from the CRF. I seemed to remember something about the CRF bottom clamp hitting the tank or something to that effect. Appreciate the input....
  11. Stretch67

    Stretch67 Mad Scientist

    Joined:
    Mar 22, 2006
    Oddometer:
    8,414
    Location:
    Bent, But Not Broken
    That was my experience as well, one hell of a racket with the old cam chain, a quiet purr with the new one. I also removed the Automatic Decompression stuff from the camshaft while I was in there, silencing the valve train even further.

    I bought new cam chain guides, but when I got everything apart, the old ones looked really good. I did put the new ones in though, since I was already elbow-deep in XR4.

    And for those readers just now joining us...
    The late-model CRF450 Cam Chain, Honda Part # 14401-MEN-A31, won't work on an XR400... too short. Ask me how I know.

    The correct part number is Honda 14401-MEB-671, having 112 Links, to fit a 2002-2008 CRF450.
  12. Stretch67

    Stretch67 Mad Scientist

    Joined:
    Mar 22, 2006
    Oddometer:
    8,414
    Location:
    Bent, But Not Broken
    Hey, dude. I'm not any help regarding the tank, but thanks again for the frame. :freaky
  13. Brewster

    Brewster Adventurer

    Joined:
    Apr 16, 2011
    Oddometer:
    43
    Location:
    Arizona
    I'd guess there would be a clearance problem as its a pretty close fit with the stock forks and the IMS tank.
    The larger diameter fork tubes would have to present a clearance problem. You might have to go back with a stock gas tank as the IMS, as you know is a tight fit.

    [​IMG]
  14. mvg2

    mvg2 Been here awhile

    Joined:
    Jul 1, 2007
    Oddometer:
    175
    Location:
    Pittsburgh, PA
    Wowzers is that clean!!!:eek1 Nice bike

    On a unrelated note, the momentum of getting the bottom and top end back in harmony is picking up. Recieved my new countershaft, crf chain, and a couple of different jets to experiment with.

    Machinist said the cylinder bore was out of round and that explains the heavy build up on the piston. Now just to find some time between finals and work...
  15. Stretch67

    Stretch67 Mad Scientist

    Joined:
    Mar 22, 2006
    Oddometer:
    8,414
    Location:
    Bent, But Not Broken
  16. Brewster

    Brewster Adventurer

    Joined:
    Apr 16, 2011
    Oddometer:
    43
    Location:
    Arizona
    I'm sure its probably possible, but I'd be afraid of putting a hole in it and destroying an expensive tank.
    I think its best to find out exactly how much reshaping would be involved first, and possibly finding a donor tank to experiment with.

    Good luck.
  17. Stretch67

    Stretch67 Mad Scientist

    Joined:
    Mar 22, 2006
    Oddometer:
    8,414
    Location:
    Bent, But Not Broken
    Nah, not a torch, just a heat gun. Mine has variable heat control, and you can vary the distance from the heat gun to the tank. Go slowly and finesse the plastic a fraction of an inch at a time.

    Or if you're nervous about using any kind of external heat source, you can fill the empty tank with [very] hot water and work the plastic around once it gets warm and flexible.
  18. Skought

    Skought Shadetree Mechanic

    Joined:
    May 5, 2009
    Oddometer:
    89
    Location:
    East of the San Francisco Bay Area (Tracy)
    took an early morning ride to my local OHV

    <table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/YY2GiyI1CIAkCkDXrBMyVdMTjNZETYmyPJy0liipFm0?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-JT50qv_tXRo/UXSe99SIBbI/AAAAAAAAGfM/0mEAVke6lGA/s800/644637_493068460760123_1818486521_n.jpg" height="204" width="800" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/111353872179575372169/XR400?authuser=0&feat=embedwebsite">XR400</a></td></tr></table>

    :rofl
  19. aki

    aki Been here awhile

    Joined:
    Jul 13, 2009
    Oddometer:
    126
    Looks awesome. :D
  20. Faceplant

    Faceplant Been here awhile

    Joined:
    Jan 12, 2006
    Oddometer:
    255
    Location:
    Swahilistan
    Hi All,

    To the electrical wizzards, I have an Aus XR400 bike with wiring loom and have upgraded the lighting to a baja double light setup. Issue is to adapt the ricky stator into this loom as there are a darn site more wires than the US models.
    Help, can't seem to attach the wiring diagrams, can someone assist?

    Thanks