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1996 xr400r build thread

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well where to start.. I had a 99% stock 1999 xr400r about 7 years ago (fmf pipe & uni foam air filter) and an amateur flat black painting job and sold it not long after for a long love of quads.. now fast forward to this year I have bought an ssr125 pit bike and Honda cloned it and while it's a blast to ride it doesn't do everything that I want example climbing any decent grade lol. after talking to a few friends with all in agreement of buying full size bikes again I began the hunt for another xr400. The few I was coming across were very highly priced or not running basket cases.. That is until I came across a 1996 in what was posted in "good" shape needing some tlc but has a fresh cylinder and piston kit (eBay special) says that it runs great just minor work needed. I drive 2+ hours to look at it and it was very well used to say the least everything appeared to be broken, near broken or missing. A few of the issues were brakes not working, front tube has a hole, seat cover was torn, exhaust missing all bolts, chain rusted with no chain rollers, a valve type noise, fork seals leaking and a completely trampoline like rear shock. Asking price was $1200 (wow) after looking it over to say I was disappointed was an understatement but yet I still pondered the idea of tearing it down and rebuilding to my liking (knowing the money spent would far exceed the worth of the bike) after much dickering back and fourth it left with me in the back of my truck for the low bargain price of $500! and so the adventure begins!! This is going to be my first build thread so bear with me and I will do my best to take many pictures and as much info as I can


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and everyone loves pictures so here are some from the previous owners add when I purchased it..Screenshot_20170525-184706.png00F0F_4AUqal7Dr7H_600x450.jpg00M0M_jJmCvt51THX_600x450.jpg00n0n_jZ8RX1Tx9dr_600x450.jpg00X0X_l3ICfj388i2_600x450.jpg00000_6Kxh2h3SXD1_600x450.jpg

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thinking the seat just needed a seat cover I ordered a nice all black gripper style seat cover. upon removal of the factory seat cover I noticed that the foam was too far gone and badly damaged.. I removed the old foam and am looking at ordering a ceet medium firmness seat foam if anyone has any experience I would love to hear about them. IMG_20170515_101753277.jpgIMG_20170515_101758697.jpgIMG_20170515_101801550.jpgIMG_20170515_165224616.jpgIMG_20170515_165227522.jpgIMG_20170515_165320315.jpgIMG_20170515_165234908.jpgIMG_20170515_165744686.jpg

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alittle more work done. separated the rear suspension to start work on that. and taken the motor out of the frame and dropped off at a good friends to be torn into to diagnose the engine noise (not your typical xr noise) my previous xr was his before it was mine and he performed all the maintenance/precautions so it's in good hands! finally some parts showed up so hopefully this weekend I can get the frame all cleaned up and start into the rear suspension!IMG_20170518_070144046.jpgIMG_20170519_064948956_TOP.jpgIMG_20170519_065437580.jpgIMG_20170519_065455261.jpgIMG_20170519_065442285.jpgIMG_20170519_065447456.jpgIMG_20170519_064953750.jpg

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Will be following the build , I have a 96 and it is my go to bike, I let friends ride my other newer 400's, Your ahead of the game with it all coming apart. only weakness in the 96 is the kick start shaft, but proper starting techniques you should break it. 500 bucks was not bad , I picked up a 2002 a few years back for 700 with title , it had broken spokes, missing parts and not running, got it running and replaced missing parts it was a good loner bike for 2 years and last year I did the top end and she is a peach now. Best of luck going forward with this build.

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Will be following the build , I have a 96 and it is my go to bike, I let friends ride my other newer 400's, Your ahead of the game with it all coming apart. only weakness in the 96 is the kick start shaft, but proper starting techniques you should break it. 500 bucks was not bad , I picked up a 2002 a few years back for 700 with title , it had broken spokes, missing parts and not running, got it running and replaced missing parts it was a good loner bike for 2 years and last year I did the top end and she is a peach now. Best of luck going forward with this build.



thanks I thought it was a good deal at $500. I'm 6' and 170 with that said I'm not too worried about the shaft issues for now if it does break down the road I will address it but for now I have enough problems lol. I am currently working on rebuilding my rear master cylinder then I will move to the caliper. fun fact I thought the master was seized on first thought as I had no rear brakes it turned out to be the pedal was "stuck" in the frame (I should have taken a better first once over) but in the end all of the brakes will be new/rebuilt and much safer! of course will post pictures showing progress

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well the pictures of rebuilding the rear master cylinder did not come out well. anyways onwards with the project motor update: my friend called who is doing the motor work and said the noise I had picked up turns out to be the timing chain being stretched. with the head examined the camshaft was worn and valves appeared to be original. timing guides were all gauged up. lastly the clutch was smoked... not good news for me or my pocket. NEW parts have been ordered and dropped off to him including: tusk full engine gasket set. oem valves and valve seals. crf450 timing chain. oem automatic chain tensioner. oem style camshaft (with the decompression mechanism) tusk stage 1 clutch kit with stage 1 springs. oem timing chain guides. moose magnetic drain plug. hoping this is it for major engine work!

 

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can everyone see the pictures on this thread? showing up as a torn picture thing on mine!

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I had a little bit of free time tonight so I started on the rear swing arm rebuild. I cleaned it all up and installed a swing arm bearing kit, oem chain slider/protector, oem style decals, russell stainless steel brake line with new oem brake line clamps. also rear caliper is removed awaiting cleaning and a rebuild.

 

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How was that swing arm pivot bolt coming out? I had a heck of a time on mine. Awesome find man.


well knowing how much of a pain and destroyed they sometimes can become I purchased a used one as a "spare" on ebay. I sprayed WD-40 before work and after work for a couple days and tilted the bike around to make sure it infiltrated, put my impact on one side and some light tapping and out it came! honestly 1/5 times that will happen but I will be giving it a grease bath before reinstalling!
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98% of my plastic is in except for the side panels (which have been ordered) my acerbis hand guards (also ordered) the front headlight shroud is out of stock on eBay and am awaiting it to come back in stock. also as a bonus my friend who is doing the work with my motor is done! and he just purchased an 01' xr400 himself! another friend of ours just purchased a 90' xr250 which will make our group alittle bit bigger I will update tomorrow with some pictures of the bike and parts in the garage and see if I can snag some pictures of there new bikes :)

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NICE it is one lucky xr400 to be saved by some one who cares. the pore thing has had a very hard life by the looks of things. sad that people abuse theyr bikes like that when there are plenty of others who cannot afford one in the first place.......good to see pix as you progress..... good show:thumbsup:

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More...MORE!!


I will be posting some more pictures along with an update on the next hour or so!
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here is a few shots of my new plastics (acerbis) next to my old stock plastics. I read mixed reviews online about these but I am very happy with them both were ordered in the plastic color code 00' cr redIMG_20170713_175953922.jpgIMG_20170713_180007059.jpgIMG_20170713_180011224_TOP.jpg

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finally I had a couple hours to spare in the garage! the rear caliper is rebuilt I used alot of elbow grease a moose rebuild kit and a shindy piston. it is a little pitted but it's not a show bike so I will just deal with it for now. IMG_20170713_165529749.jpgIMG_20170713_165533951.jpgIMG_20170713_165632632.jpgIMG_20170713_173113873.jpgIMG_20170713_172741775.jpgIMG_20170713_172745818.jpgIMG_20170713_172749138.jpgIMG_20170713_174857923.jpg

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