1997 XR400 Build

I am starting this thread to show internetz people my new (to me) project.

It is a 1997 Honda XR400.

Here is a picture. Bask in its glory...



I took delivery of this monster (I picked it up, drove home and then promptly decided to unintentionally drop it out of the truck bed almost squishing myself (because I'm dumb and didn't get help (but it only weighs a little over 2-hundo (250lbs+... @t4daddy )... So it's alright))) this last weekend, on the 21st. Runs great. Starts on first kick.

The guy I bought it from is my sisters boyfriend, and good friend of mine so I know a lot of the history of the bike. He got it titled and "road legal" ... Mostly...

Things he did.

*Eline stator
*Eline lighting kit
*mitas enduro tires (apparently they are good. They ride great!)
*crimped exhaust tip to make up for missing baffle. He's afraid it was running lean and thinks that fixed it. (It needs a new baffle and exhaust tip now)
*busted off the kickstand...
*wu tang stickers

Things I'm going to do.

*tusk lighting kit - pending installation
*trail tech vapor speedo/tach/temp/ind lights etc display - pending installation
*fabricate custom mount for dual hella 500 lights - getting close
*rectifier/regulator to charge battery - pending installation
*battery (tusk lipo battery included in the kit is a laugh)
*fabricate custom pannier rack for the rear sub frame. - pending inspiration
*mikuni pumper carb
*fix stock exhaust
*get it inspected so I can ride the thing...
*cosmetic stuff. Fresh plastic and decals etc... - got it covered
*beefier front springs... Non critical
*fix kickstand

Goals for the bike are to have a good short distance commuter/grocery grabber. Where I live there are no highways so I don't need speed. There are a lot of single track trails to explore, and nice scenic areas to enjoy. This bike will be purely for fun. I needed something a little different.

Stay tuned

Thanks for lookin

 

They are decent cruiser/trail bikes. Makes awesome low end power. But "just over 2 hundo" is a pipe dream. Ready to ride those bikes are closer to 3 hundo. Also, I'm not sure what "crimping the tail pipe to fix the lean issue" even means? That would all be in jetting, and if no aftermarket exhaust there "should" be no need. But concrats, they are built like tanks for the most part.

 

250 some odd pounds, Wet. A little over 2 hundo that's the same, right?

Anyway I am re jetting the carb. His reasoning was he wanted more back pressure because he removed the baffle and was afraid it would run lean... The spark plug has a nice nutty coloring to it, and doesn't look like it has been run hot. But either way I want to re jet to be safe, and I have to fix the exhaust because the end of it looks like a puckered a-hole. that bothers me. I need to find a new baffle as well. Not a big deal.

 

Took the plastic off and started making heads and tails of the stock wiring and the aftermarket lighting kit. Somewhat of a rat's nest, but I think I have a good starting point. I'm replacing the non stock wiring harness with the tusk Enduro lighting kit. should hopefully be pretty straight forward! The biggest thing is going to be fabricating aluminum brackets to mount everything to.

 

Wish I grabbed a picture of this... Gas tank was being held on by weed whacker cord... And zip ties.

 

Took more off. Debating if I want to pull the motor out to give it a good once over and to have easy access to the frame to re-weld the kickstand.

Also mocked up a template to mount my pair of hella 500s to.




Then cut it out of aluminum and mounted it. Still debating positioning of lights, but this will give me plenty to mount the computer and other goodies to.


About to cut out, and weld on the brackets for the lights to mount to.

 

Subbed

 

Congrats on your new XR. should look into the mikuni pumper carb, they do wonders. I have a 2001 xr400. Simple.bikes and will go forever if you treat them right XR'Sonly.com. is a good vendor when your looking for parts fyi...subbed

 

You won't believe what page I was just looking at when I came over here to see what the hap is! The pumper carb on xrs only!

Out of stock though...

I have the oil temperature dip stick from them!


Awesome lookin bike man! Do you have the long range tank?

 

Thanks! Yep it's a desert tank, holds a bit over 3 gallons I believe. Xr's site can hurt the wallet haha.

 

Not unlike TacomaWorld...


We're in the middle of a decent little "storm" right now, so can't get anything done on the bike. I'm getting a little stir crazy!

By the way, what bark busters are those? I'm looking at the highway dirt bike hand guards. Like the fold out mirrors and integrated top clamp and blinkers. (Not my bike)

 

Need opinions on which way to mount the headlights. Next to each other or stacked vertically on the aluminum fairing i made.

One way isn't better than the other, it's just purely aesthetic.

 

Subd I miss riding dirt. No where to ride anymore out my way

 

Sorry to hear man! not a ton here, but enough to have fun!

 

horizontally

Vertically


Give ya a rough idea

 

I like the horizontal mounting best I think. Just my $.02.

 

Horizontal ftw

 

Thanks man! I still can't decide...

 

Those are cool...mine are cycra

 

Awesome! Those look really sharp! How do they hold up? Pretty strong?