Sepo XR400 Rebuild

[ChrisMember]

I have an XR400 as most know and it has some frame damage. The damage is mainly underneath the frame due to rust. It appears that at some point the kick stand was torn off as well and re-welded but is cracking again.

I decided to tear it down and repair the damage. I thought I’d also take the opportunity to replace, clean up and make some modifications to this great all around bike. I decided to wait to do the motor until it was required.

Some history on the bike…

It is a 1996 Honda XR400R build date 05/1996. I bought the bike in April 2009. The guy who owned it before me stripped all the electrics, speedo etc I suppose to pretend it was a motocross bike. He didn’t keep anything. I paid $2000 for it.

I sourced all the needed parts from wreckers, ebay etc. to get all the electrics and speedo back on and replaced the brake pads. I then rode it pretty much as is for about 8 months or so then in January this year I started replacing and repairing things.

Work Done in Stages

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First round done in late January 2010. I did a valve adjustment, auto decompresser removed, carby cleaned and new tires front and rear. Tires were Kenda Carlsbads. I also stripped the white plastics and replaced with Honda Red plastics leaving the tank White and Added a wiz-bang XR sticker.

Second round done in mid March 2010. I had the suspension front and rear completely rebuilt by shock treatment in Walacia. .46 or .47 front springs with gold valves and 11k rear spring, rebuilt and chrome shaft re-chromed and 10w motorex oil. I added bar risers that raised the bars and moved them forward 22m each. I registered the bike at this time as well.

Third Round done in Mid April 2010. Replaced Front and Rear sprockets, new o-ring chain, added Shark Fin, added rear fender bag and since I did not like the Carlsbad tires I replaced them with Dunlop D952s front and rear.

Fourth round done in May 2010. Stripped bike completely down to the frame. This basically will be a complete rebuild/cleanup without doing motor.

Repaired frame damage
Cleaned up (Electric Wire brush and metal polish) all bolts, nuts, screws, calipers, swing arm, etc. etc.
Electric Wire brush outside of motor best I could until rebuild is done.
Powder coated frame, sub-frame, side stand and foot peg arms (Black)
Anodized Rims (Black)
Painted Hubs (Red)
Stripped and painted stock muffler
Re-spoked Front and Rear wheels
Installed Edelbrock Quiksilver Pumper carby and cables
Replaced Front and Rear Wheel bearings and seals
Replaced Head Stem bearings and seal
Replace Swing arm bearings and seals
Replaced Swing Arm linkage bearings and seals
Replaced Swing Arm rubber chain guard
Replaced front brake line with Braided one
Replace plastic Chain Guide with Aluminum one
Replaced Front and Rear Brake Discs
Replaced Brake Lever with MSR Grip Lever
Replaced Clutch Lever with MSR Grip Lever
Replaced Shifter with folding MSR Shifter
Replaced Fork Boots
Added A-Loop Kit – Includes Tank, Shrouds, Seat, CRF type MX Fender and Bling Kit (Gives bike modern look with flat seat and tank area)
Added AU ADR Rear Brake Light and plate mount for the CRFX bikes. (Sourced from S3 Performance)
[strike]Added Carbon Fiber Frame Guards[/strike]
Added GPS Mount Kit for Garmin GPSmap 60cx
Added Pivot Pegs – Pending

Thanks to TB for helping with the strip down and piecing it back together as well as doing some of the leg work for me.. I couldn’t have done it in 2 weeks time without him..

I used various businesses in the last excercise:

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Big thanks to Suttos Penrith – Various bits bought
S3 Performance Melbourne – Front and rear brake discs and ADR CRFX brake light/plate mount
S&R Performance Penrith – Frame repairs
Colour Coatings Pty Ltd Blacktown – Frame and bits powder coated
Anodizers Mortdale – Rims Anodized
E-Bay USA and UK – Various bits bought cheaper than in Australia
A-Loop Colorado USA – Seat and Tank kit http://www.aloop.com

Photos to come…..

[Mick DMember]

c-e-l wrote:

Quote:

Photos to come…..

Hurry up man, I wanna see how good it all looks, especially the rims

[ChrisMember]

Bike As Purchased

February 2010

Before Rebuild

[ChrisMember]

Frame Progress Photos

[ChrisMember]

Engine and other Mics Bits Cleaned Up

[ChrisMember]

Re-Assembly Begins

[ChrisMember]

Ran out of time as today it is my daughters B-Day. The final product won’t be done until Saturday.. I’ll post the finished product photos then.. I still have to assemble the A-Loop Kit and do some other odds and ends stuff..

I think TB may have some other photos of the process…

Cheers…
Chris………..

[scott bockingMember]

Awesome job Chris.

Can’t wait to see the final shots.

STM

[GregMember]

Wow that was a lot of work, building both the wheels was the hardest with Chris asking questions while I was trying to think. All the suspension bushes got replaced, wheel bearings seals and the headset bearings it was a complete end to end that should be explained. It was the first Edelbrock pumper carb I have fitted and without any instructions took some thinking. Once the throttle tube and cables were lubed happy days. It was good seeing Chris get excited about learning bits and pieces tricks using sockets to push bearings etc.

Some photos I took

Back wheel when I finished assembling it, rim anodised, hub painted and new spokes, front the same, also fitted new disc’s

Frame at the start

Boxes and boxes of bits

Edelbrock Pumper carb

TB

[GregMember]

c-e-l wrote:

Quote:

Thanks to TB for helping with the strip down and piecing it back together as well as doing some of the leg work for me.. I couldn’t have done it in 2 weeks time without him..

I used various businesses in the last excercise:

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Big thanks to Suttos Penrith – Various bits bought
Yeah Thanks Mal as always, this is the third project bike I have been involved with as always Mal you come through, be it a Suzuki motard project bike, a A4DE assault with a Husky or an XR400 refurb thanks champ

Anodizers Mortdale – Rims Anodized –
They anodised the rims for this project and the Mayors for $88.00 per set including the G bargain in anyone’s language. If you are thinking about getting your rims done I recommend them, for a tiny fee I will also strip your rims and re-lace them after they are done

TB

[Mick DMember]

Looking awesome so far. You have a good man on the job helping you Chris. Not only does he like spannering…he just loves bling and Hondas.

[Mark BuntingMember]

Well done CEL the XR’s looking great. For a Honda that is

TB your a champ. Always ready to lend a hand

[ChrisMember]

micknmeld wrote:

Quote:

Looking awesome so far. You have a good man on the job helping you Chris. Not only does he like spannering…he just loves bling and Hondas.

micknmeld wrote:

Quote:

Awesome job Chris.

Can’t wait to see the final shots.

STM

Thanks Fellas.. Yeah TB loves holding a tool in hand.. :woohoo: Great leader as well!! This apprentice pretty much learned everything needed to fully maintain my bike without paying someone else to do it for me now.. The process of replacing all the bearings and I mean ALL, every bearing and seal that is on the bike was an interesting and a long drawn out exercise.. Took nearly 3+ hours, removing old sleeves, collars, bearings crazy stuff..

I will however be buying TB a Vice for his birthday… Man has everything a motor bike workshop needs except for a Vice!!! :woohoo: :silly: :laugh:

I was a bit disappointed I didn’t have more time so we could have completed it at TB’s.. TB got to play with the carby though.. He managed to get it on and re-cabled with minimal drama.. Then after about 6 kicks she fired right up.. The famous XR400 bog is now gone and I can’t wait to get it on the trails for a power test or 2..

I think once I finish it up Saturday me and some mates will ride up to TB’s so he can enjoy it and his work in the flesh…

When she runs now the sound she makes Baaalingggg ing ing ing Baaalingggg ing ing ing Baaalingggg ing ing ing :woohoo:

[Mick DMember]

c-e-l wrote:

Quote:

When she runs now the sound she makes Baaalingggg ing ing ing Baaalingggg ing ing ing Baaalingggg ing ing ing :woohoo:

Sounds like Two stroker???

[Justin WilliamsMember]

Well done c-e-l and TB… :woohoo:

Awsome Job…. :woohoo:

[Author]

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