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      JUST IN!   04/24/2018

      HOW TO: 4-STROKE PISTON REPLACEMENT DONE RIGHT!

michaelxr

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About michaelxr

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    California
  1. Yes sir. I used a 160 main and 60 pilot and I can't remember the needle but it was a 49 state legal needle from a 1996 XR400 on the middle clip. I ride 3000 to 7000 ft and this worked for that elevation. It was a bit rich at 7000 but spot on at 3000 ft and 75 degree temp. I have CHM exhaust with header welds ground. Uni filter, snorkel removed. I would turn the fuel screw closed until it would stumble then open it back up 1/8 to 1/4 turn. And I completely agree with the CA gas, you have to run Stabil. My buddy just bought another buddy of mine's Tw200 for his wife. TW was in great condition and I had ridden it many times it ran perfect. Well it sat for a while before my buddy bought it. We got it home started cleaning it up and started it up and it ran horrible. We pulled the carb and everything inside was corroded so bad he just bought a new carb for it. I don't think we could've salvaged it even with all new jets.
  2. To me, my STREET LEGAL XR400R is the best bike ever. I can go wherever I want on it (within the law). Not too heavy for trails, not too light for short freeway jaunts. Enough power to get me out of sticky situations, not too much power to put me into sticky situations, because I'm not that great of a rider. It's the "goldilocks" of dirt bikes. It works very well for about 80% of the dirt biking community. It's funny because I still see very good shape XR400R's selling for same or even a little more than similar year CRF450's. I think they hold their value very well because they are such a do everything decent bike.
  3. I was able to convert a Talon rear hub specific to a XR650R to fit my XR400R using the following parts: 56-063 XR400 Rear Spacers (TALON HUB) 55-861 XR400 Rear Axle Tube (TALON HUB) The XR650R wheel had a 20mm axle and the XR400R has a 17mm axle. Those are TALON part numbers. The 55-861 axle tube is the same outside diameter, so the seals and bearings were fine, it was just a thicker tube towards the inner diameter, which brought it down to 17mm. I had a local machine shop do the work. The wheel/hub was too pretty for me to try banging on it. If I remember right, XR650L wheels will swap onto XR400R. I believe the same is true for XR600R. XR650R front will fit, XR650R rear will need the two parts above. If you try a CRF wheel, I believe the hub is wider and the sprocket and rotor surfaces are too wide and won't line up with the caliper and chain. I posted a link to a spreadsheet that QTMI.com had posted on their website. They didn't have any links to it at the time, but I searched on one of the parts above and it came up. It listed all the talon hubs and all the dimensions. Inner and outer diameters on everything, then listed part numbers for all the parts inside the hub. It was a wealth of knowledge. The link I had no longer works, and stupid me, I didn't just print it to PDF and keep it for myself for later reference. But I think for our bikes, only the bikes I listed above will work on a Talon wheel swap.
  4. I have one on my bike. It's a completely stock motor with Uni air filter and free flowing exhaust. I did it several years ago, got out of riding for a few years, now getting back into it. I have no bias any more to justify why I spent $400 on a carb like I might have recently after I bought it. I don't notice any difference in performance with the pumper. Maybe a tiny bit improvement off idle. I didn't have any bog with the stock carb after getting jetting advice and parts from Carmichael Honda in Sacramento. Stock carb ran great. The biggest difference for me is the starting. I hadn't started my bike in over 6 months. I'm getting ready for a ride next month and decided I better pull it out of the corner of the garage and start going through it to make sure it's ready to go. My 8 year old son was in the garage with me and asked to go for a ride before I put it up on the stand and started working on it. I reluctantly said OK, as I really didn't want to kick on it for a long time for a trip up the street and back. Choke on, gently pushed the motor through getting to the compression, let the kickstarter back up to the top, gave one half twist of the throttle, one good kick, and it started right up. More than 6 months in the corner of the garage between the last start. If that had been stock carb, I would've wheeled it out in the gutter for a little more leg room, let the sun shine on the engine for awhile, gone through the whole routine, and pray that if I got it to fire I could keep it going. I do find I have a harder time with the tuning of the pumper than the stocker. The mid to upper range is fine, my problem is idle circuit. I can't get the lean popping out of it on deceleration. If I crack the throttle just the tiniest bit as I'm decelerating, no popping. If i just let it close all the way, pop pop pop pop. If I adjust the fuel screw any, it just makes it run worse where it matters. The decel pop is not a big deal, just annoying. I think I agree the pumper is less sensitive to altitude and weather changes than the stock carb. Edited to add... I guess I'm getting old and busy with life, 3 kids. I just want my bike to run and be fairly low maintenance, (which is why I still have my XR400). If I can't have electric start, I'll take easy kickstarting. To me that's where the pumper is worth it.
  5. Just got back from a 300 mile supermoto weekend from Murphy's CA to North Lake Tahoe and back. I properly adjusted my steering stem after our last trip so it wasn't loose anymore and I'm happy to say it was rock stable. I was cruising at 65 mph with one hand in some spots. No shimmy or shake whatsoever. Actually it seemed too stable so I'm going to raise the forks in the triples a little to see if I can get it to want to turn a little better now. But even if it stays like it is, it's very comfortable on the road. It ran like a top and seems to keep up with my buddy's KTM 450 EXC supermoto pretty well. Up on the passes at 8000 to 10,000 feet it feels a little sluggish and his bike can pull away from me very easily, especially on uphill grades. But when we're back down to 2000 feet or so, mine really comes alive and he only pulls on me a bike length or 2 up to 50 mph or so under WOT acceleration, and of course, his 6th gear has it all over me in top speed, but we did pass a few cars in a passing lane today and got my XR up over 80 to get around some motor homes and I think it had even more. I was surprised it would go that fast. Great trip though, still loving the supermoto setup. I'm still amazed at how versatile the XR400R is with a few adjustments to whatever riding conditions you throw at it. Street, desert, nasty rocky trails, fireroads, reliability. It just does it all pretty dang well with the right gearing and setup for the situation.
  6. Here's a picture of mine. I call it a XRF400SM
  7. I don't mean the actual sidewall of the tire in the post above, but the farthest tread on the edge of the contact patch.
  8. I got these Maxxis rain tires on ebay from that dude that's selling them for $47 each including shipping. I got these tires for under $100 so I decided I had to give them a try. The 160 fits fine on the 4.25" rim. I changed to a non-oring chain to get some more clearance, but I have about 1/4" to 3/8" clearance from the sidewall. The 160 on the 4.25 wheel though does make it really rounded over. There's no way I'll ever be able to use the sidewall on the rear tire cause I think I'd have to be dragging the bar to get to the sidewall. No clearance issues though. My next set of tires will most likely be Continental SM's and a 150 on the rear to get a little flatter profile on the rear. I just wish I had a little more power. When you're running 7000 feet plus up over the passes, heading uphill, my 400 gets a little winded. I'd absolutely love to have a plated uncorked XR650R with my sumo setup. Man to me that would be the ultimate.
  9. No. I'd never heard of that. But I will be doing that this time. Thanks! Great tip.
  10. What does pillow style mean?
  11. My XR has been burning up muffler packing in like 200 road miles. I have a CHM round tube muffler with their quiet insert and it's super loud. I drilled out the rivets and there was a scrap of packing material left in it. The rest came out in teeny tiny balls of melted fiberglass. I bought some FMF muffler packing, cut it to the right length and width, rolled it up over the screened tube and riveted it back in. Went for a supermoto road ride this past weekend, about 240 miles. It was quiet to start with, now once I'm home I ride it around and it's super loud again. I bet there's just some scraps of packing left if I pull it apart again. My bike is jetted to run at sea level, and the plug color and performance at sea level is correct. I went for this ride from 4000 to 10000 feet this weekend and it ran real rich the whole time, I didn't bother to rejet. Could the rich running have been flaming up in the muffler and turning the fiberglass into little tiny balls of melted glass? I can't think of any other reason it would do that other than the fiberglass packing was in direct contact with flame. Any ideas? Thanks!
  12. Sonora pass was awesome, we were going West to East and there's one downhill right hand 20 mph corner on the eastern downslope that we came into pretty hot and I really had to get on the brakes and my new 320 mm Braking front rotor just stopped me on a dime. I would've been real worried with my stock rotor, I don't think I could've slowed up quick enough to enter the corner. That section over the top of the pass and heading down the eastern slope was the most fun I've ever had on any motorcycle. The money I spent on my sumo setup paid for itself in my mind in that 10 or 15 mile stretch. I had an ear to ear grin the whole way down through those twisties. I not only got a kick out of the handling, but the braking is just phenominal. Yes, I've been over monitor and ebbets passes, which is where our next trip will take us. I did it on knobbies a few years ago. I can't wait to do it on my sumo setup.
  13. I'm in Modesto, CA. Central valley 70 miles south of Sacramento. My wife dropped us off in Mi-Wuk up 108. We rode over Sonora pass to 395, then out to Bodie near the CA/NV border, then south on 395 to Lee Vining. Next morning we rode Tioga Pass Road highway 120 through Yosemite to Groveland where my buddy's wife picked us up. It was an awesome ride. About 240 miles or so total. Sonora pass was better riding with great scenery. Tioga pass wasn't as twisty and had tons more traffic, but it was absolutely gorgeous going thru the high country of Yosemite.
  14. You know, my steering headset was just a tad loose. We rode over the pass, then out to Bodie ghost town via 13 miles of nasty dirt road, (worst part of the trip). By the time we got back on the pavement, I think my bearing races seated completely and left me with them just a little loose. I could feel it going over rocky bumps kind of a klunk in the front end. I got home and sure enough, it was loose. I'm hoping that's what the problem was with my instability. It wasn't tank slapping, but I couldn't hold the bars tight enough to keep them from wobbling back and forth. If I'd eased up on my grip, maybe it would've tank slapped. But I put 15/40 gearing on it, got a 160/60-17 Maxxis Presa rain on the rear and a 120/70-17 Maxxis Presa rain on the front. Had my local bike shop mount the tires and balance them before I left. We came out of Bodie heading back towards 395 and there was a long straight on a nice smooth road, so I opened it up to see if I could put any distance on my buddy behind me on his KTM 450. I was surprised at how much top speed I had with this new gearing, but it was nearly 80 and still had some to go and it started wobbling, so I got out of it. Next time I will definitely rejet my Mikuni. It was fat the whole way, which was about 4000 ft up to 10,500 ft at Saddlebag campground on Tioga pass road. It was burbling every time I'd shift. When I was hammering the throttle it never stumbled, only if I let it coast a ways, or took my time between upshifts, it would load up and stumble getting back on the gas. I got the same mileage as my buddy on his 450 so that should tell you I was rich. I expected to fill up every other time he filled up, but we got nearly identical mileage. I live at sea level and my pumper is jetted for that. I will definitely take the extra 30 minutes or so it takes to rejet it for next time.
  15. Thanks. I did that before I left, they are not flush, but maybe 1/4" out of the top of the clamp. It was rock solid until about 70 mph, then I'd get a little wobble. I think I got up to nearly 80 at one point and the wobble got to where it wanted to start tank slapping no matter how hard I tried to hold the bars so I backed out. We were mostly 30 to 50 average and it was perfect for those speeds. That was my first trip out in supermoto trim, we got into some twisties heading east over sonora pass in the sierra's and that section of about 10 miles or so turned out to be the best time I've ever had on my motorcycle, dirt or street. We were carving corners and with a 320 mm rotor on the front, could come hot into corners and just absolutely stop on a dime. My buddy has a 2007 KTM 450 EXC-R street legal from the factory with supermoto wheels and Michelin Pilot tires and my old XR400 was able to keep right up with him.