[GregMember]

chris72a wrote:

Boony wrote:

we should add an apreciation certificate signed by us all for their wall. :huh:

that water park thing will send you straight back to king status scotty, maybe you could show that new one we have some tips hey, :whistle:

Happy to chuck in for the chockies and flowers , they do look after us.

Boony

Thats a rare good idea of yours boony, I can do some certificates of appreciation up and get them laminated or something.

I can supply frames for them to go in

TB

[GregMember]

Yeah the Purple Pub is already on the must do list. I will make sure I get plenty of photos of Wepia for you

TB

[GregMember]

menace wrote:

i reckon we need to buy Rosie some flowers and chockys for lookin after all us

she seems a good egg

Plus 1 Menace good idea cant hurt us next year. I will chcuk money at that if someone organises it

TB

[GregMember]

Wow! That looks awesome well done mate better than new comes to mind

TB

[GregMember]

I have a set of the Multipack Cruize glasses and they are awesome, I use the yellow lenses driving at night the clears on the bikes in the wet the sunnies all the time.

TB

[GregMember]

It will be navigation only as well, I like the format and the idea of riding my own ride all day

TB

[GregMember]

Dejay wrote:

That will work, but I’ll strap it to me because I tend to exit the vehicle every now and then!
:woohoo: :silly:

[GregMember]

Ace wrote:

Trailboss wrote:

Ace and Eags I am pre running part of it this on Saturday but because I am going to the Cape am missing the actual ride :pinch:

I am doing the ride with a St Aburns start and finish, some extra changes and bits and bobs again in September date to be announced if you are interested.

Will be a Friday arvo arrival at St Aburns, camp across from the pub and go Saturday morning return Sunday arvo
TB

No good for me…babysitting the kids :pinch: …i mean looking after my kids :whistle: Sounds like a great ride though mate.

Did Settlers Rd from St Albans last weekend…freshly graded…just the right amount of rain…perfect :woohoo:

No read it with your eyes open :laugh: I will be doing it AGAIN IN SEPTEMBER

TB

[GregMember]

Bulls Wool wrote:

:blush: oh yeah, yes it’s an xr 400. & thanks for the link but they didn’t seem to have it there either (unless they’re caring it somethimg else) there is reference to general sized engine bolts for torque so I’ll give rock a call and go with 39 Nm.
Cheers all !!
B.W.

Would only do it to about 22nm myself be that it is in that alloy post. Locite it also

TB

[GregMember]

Hope this helps

Honda XR400R Technical Specifications

This is a test thread to agree a layout for technical specifications threads on other bikes. Comments on usefulness, layout, etc.. very welcome.

These specifications are intended as a guide and do not constitute official measurements or specifications. If you are unsure please get a Honda approved mechanic to check or maintain your bike.

All units in millimetres mm (inches in) unless otherwise specified.

Honda XR400R
Covers the years (’96 to date).
Please post up specs for pre ’96 models if you have them.

Pictures

Dimensions
Length: 2130 mm (83.9 in)
Width: 840 mm (33.1 in)
Height: 1240 mm (48.8 in)
Wheelbase: 1425 mm (56.1 in)
Seat Height: 930 mm (36.6 in)
Ground Clearance: 310 mm (12.2 in)
Dry Weight: 116.5 kg (257 lbs)
Curb Weight: 125 kg (256 lbs)
Maximum Weight Capacity: 100 kg (220 lbs)

Frame
Frame Type: Semi-double cradle
Front Suspension: Telescopic fork
Front Wheel Travel: 280 mm (11.0 in)
Rear Suspension: Swingarm
Rear Wheel Travel: 300 mm (11.8 in)
Front Tyre (Tire) Size: 80/100-21 51M
Rear Tyre (Tire) Size: 110/100-18 64M
Tyre (Tire) Brand (Dunlop) FR/RR: K490G/K695
Front Brake: Hydraulic single disc
Rear Brake: Hydraulic single disc
Caster Angle: 25 degrees 15′
Trail Length: 94 mm (3.7 in)
Fuel Tank Capacity: 9.5 l (2.5 US Gal, 2.1 Imp Gal)
Fuel Tank Reserve Capacity: 1.5 l (0.4 US Gal, 0.3 Imp Gal)

Engine
Cylinder Arrangement: Petrol (Gasoline), air cooled 4-stroke SOHC
Bore and Stroke: 85.0 x 70.0 mm (3.35 x 2.76 in)
Displacement: 397 cm cubed (24.2 cu-in)
Compression Ratio: 9.3:1
Valve Train: Silent multi-link chain driven SOHC with rocker arms
Intake Valve Opens at 1 mm Lift: 11 degrees BTDC
Intake Valve Closes at 1 mm Lift: 41.5 degrees ABDC
Exhaust Valve Opens at 1 mm Lift: 40 degrees BBDC
Exhaust Valve Closes at 1 mm Lift: 10 degrees ATDC
Lubrication System: Forced pressure (dry sump)
Oil Pump Type: Trochoid
Cooling System: Air cooled
Air Filtration: Oiled polyurethane foam
Engine Weight: 38.5 kg (85 lbs)

Carburettor (Carburetor)
Carburettor (Carburetor) type: Piston valve
Throttle Bore: 38 mm (1.5 in)

Drive Train
Clutch System: Multi-plate, wet
Clutch Operation System: Cable operating
Transmission: 5 speeds
Primary Reduction: 2.826 (65/23)
Final Reduction: 3.000 (45/15) *Note – Gearing varies from country to country. Some have 40/15 as standard.
Gear Ratio 1st: 2.615 (34/13)
Gear Ratio 2nd: 1.842 (35/19)
Gear Ratio 3rd: 1.400 (28/20)
Gear Ratio 4th: 1.120 (28/25)
Gear Ratio 5th: 0.926 (25/27)
Gearshift Pattern: Left operated return system 1 – N – 2 – 3 – 4 – 5

Electrical
Ignition System: CDI (Capacitive Discharge Ignition)

Lubrication System
Engine Oil Capacity:
at draining 1.7 l (1.8 US qt, 1.5 Imp qt)
at disassembly 2.2 l (2.3 US qt, 1.9 Imp qt)
at filter change 1.8 l (1.9 US qt, 1.6 Imp qt)

Recommended Engine Oil: Honda GN4 or HP4 4-stroke oil or equivalent motor oil. API service classification: SF or SG Viscosity: 10W-40 or 20W-50.
Oil Pump Rotor:
Tip clearance: 0.15 (0.006)
Body clearance: 0.15 – 0.22 (0.006 – 0.009)
End clearance: 0.02 – 0.09 (0.001 – 0.004)

Fuel System
Carburettor Identification Number: *Note – Other countries may have different models.
’96, ’97: PDK1A
After ’97 (49 State Type): PDK1C
After ’97 (California Type): PDK1E

Main Jet: *Note – Other countries may vary jet sizes.
’96, ’97: #162 (standard setting), #158 (suggested settings for trail riding)
After ’97: #142

Slow Jet: *Note – Other countries may vary jet sizes.
’96, ’97: #62 (standard setting), #60 (suggested settings for trail riding)
After ’97: #52

Jet Needle Clip Position: *Note – Other countries may vary clip positions.
’96, ’97: 3rd groove from top (standard setting), 2nd groove from top (suggested settings for trail riding)
After ’97: 3rd groove from top

Pilot Screw Opening: Factory setting 2 1/4 turns out
Float Level: 14.5 mm (0.57 in)
Idle Speed: 1300 +/- 100 rpm
Throttle Grip Free Play: 2 – 6 mm (1/8 – 1/4 in)

Cylinder Head / Valves
Decompressor Lever Free Play: 5 – 8 mm (3/16 – 5/16 in)
Cylinder Compression: 686 – 980 kPa (7.0 – 10.0 kgf/cm squared, 100 – 142 psi) / 450 rpm
Valve Clearances:
IN: 0.10 +/- 0.02 (0.004 +/- 0.0008 )
EX: 0.12 +/- 0.02 (0.005 +/- 0.0008 )

Clutch
Clutch Lever Free Play: 10 – 20 (3/8 – 3/4)
Clutch Spring Free Length:
’96: 45.5 (1.79) Service Limit – 44.5 (1.75)
After ’96: 43.2 (1.70) Service Limit – 41.6 (1.64)

Clutch Disc Thickness: 2.92 – 3.08 (0.115 – 0.121) Service Limit 2.69 (0.106)
Clutch Plate Warpage Service Limit: 0.30 (0.012)

Front Wheel / Suspension / Steering
Cold Tyre (Tire) Pressure: 100kPa (15 psi)
Front Wheel Rim Runout Service Limit: Radial 2.0 (0.8 ), Axial 2.0 (0.8 )
Fork Spring Free Length:
’96, ’97: 510.4 (20.09) Service Limit 505.3 (19.89)
After ’97: 536.1 (21.11) Service Limit 528 (20.8 )

Fork Spring Direction: Narrow end facing down
Fork Tube Runout Service Limit: 0.20 (0.0008 )
Fork Air Pressure: 0 kPa
Recommended Fork Oil: Pro Honda Suspension Fluid SS – 7
Fork Oil Level:
’96, ’97: 100 (3.9)
After ’97: 116 (4.6)

Fork Oil Capacity:
’96, ’97: 570 cc
After ’97: 559 cc

Rear Wheel / Suspension
Cold Tyre (Tire) Pressure: 100 kPa (15 psi)
Rear Wheel Rim Runout Service Limit: Radial 2.0 (0.8 ), Axial 2.0 (0.8 )
Drive Chain Slack: 35 – 45 (1 1/3 – 1 3/4)
Drive Chain Length (at 41 pins / 40 links) Service Limit: 638 (25.1)
Drive Chain Size / Link: DID 520V8/108 or RK520M0Z6/108
Chain Slide Depth Service Limit: 4.0 (0.15)
Shock Absorber Spring Free Length: 217.3 (8.56) Service Limit 213.0 (8.39)
Shock Absorber Spring Direction: Narrow end facing down

Disc Brakes
Specified Brake Fluid: Dot 4
Brake Disc Thickness:
FR: 3.0 (0.12) Service Limit 2.5 (0.10)
RR: 4.5 (0.18 ) Service Limit 4.0 (0.16)

Brake Disc Runout: Service Limit 0.25 (0.010)

Electrical System
AC Regulator Regulated Voltage: 12/5 – 13.5 V / 3000 rpm
Spark Plug:
Standard Riding: NGK DPR8Z, DENSO X24GPR-U
High Speed Riding: NGK DPR9Z, DENSO X27GPR-U

Spark Plug Gap: 0.6 – 0.7 (0.023 – 0.028 )
Headlight Bulb: 12 V 35 W
Taillight Bulb: 12V 5 W

Torque Values
Unless specified all bolts should be tightened to the following torque values.
Standard Fasteners N-m (kgf-m, lbf-ft):
5 mm Bolt and Nut: 5 (0.5, 3.6)
6 mm Bolt and Nut: 10 (1, 7)
8 mm Bolt and Nut: 22 (2.2, 16)
10 mm Bolt and Nut: 34 (3.5, 25)
12 mm Bolt and Nut: 54 (5.5, 40)
5 mm Screw: 4 (0.4, 2.9)
6 mm Screw: 9 (0.9, 6.5)
6 mm Flange Bolt (8 mm Head: Small Flange): 9 (0.9, 6.5)
6 mm Flange Bolt (8 mm Head: Large Flange – engine only): 12 (1.2, 9)
6 mm Flange Bolt (10 mm Head) and Nut: 12 (1.2, 9)
8 mm Flange Bolt and Nut: 26 (2.7, 20)
10 mm Flange Bolt and Nut: 39 (4.0, 29)

Engine N-m (kgf-m, lbf-ft):
Oil Drain Bolt (at crankcase) 1 x 12 mm: 25 (2.5, 18 )
Oil Drain Bolt (at frame down tube) 1 x 10 mm: 39 (4.0, 29)
Frame Down Tube Oil Strainer Screen 1 x 27 mm: 54 (5.5, 40)
Oil Pipe Bolt (at Oil Strainer Strainer) 1 x 12 mm: 37 (3.8, 27)
Oil Cooler Joint Flare Nut (left side) 1 x 16 mm: 20 (2.0, 14)
Oil Cooler Joint Flare Nut (right side) 1 x 16 mm: 20 (2.0, 14)
Oil Pump Assembly Bolt 2 x 6 mm: 13 (1.3, 9)
Fuel Valve Mounting Bolt 2 x 6 mm: 9 (0.9, 6.5)
Spark Plug 1 x 12 mm: 18 (1.8, 13)
Valve Hole Cap 4 x 36 mm: 15 (1.5, 11)
Valve Adjusting Lock Nut 4 x 7 mm: 24 (2.4, 17)
Head Cover Bolt 1 x 8 mm: 26 (2.7, 20)
Rocker Arm Shaft 2 x 14 mm: 27 (2.8, 20) NOTE 1
Intake Sub-Rocker Arm Shaft 2 x 14 mm: 27 (2.8, 20) NOTE 1
Exhaust Sub-Rocker Arm Shaft 2 x 14 mm: 27 (2.8, 20) NOTE 1
Cam Sprocket Bolt 2 x 7 mm: 20 (2.0, 14) NOTE 1
Cam Chain Tensioner Plug 1 x 6 mm: 4 (0.4, 2.9)
Cylinder Head Nut 4 x 10 mm: 44 (4.5, 33) NOTE 2
Cylinder Bolt 4 x 10 mm: 44 (4.5, 33) NOTE 2
Kickstarter Pedal Pinch Bolt 1 x 8 mm: 26 (2.7, 20)
Clutch Center Lock Nut 1 x 18 mm: 108 (11.0, 80) NOTE 2, 4
Gearshift Drum Stopper Arm Pivot Bolt 1 x 6 mm: 12 (1.2, 9)
Primary Drive Gear Nut 1 x 18 mm: 88 (9.0, 65) NOTE 2
Timing Hole Cap 1 x 14 mm: 10 (1.0, 7)
Crankshaft Hole Cap 1 x 30 mm: 8 (0.8, 5.8 )
Flywheel Bolt 1 x 12 mm: 127 (13.0, 94) NOTE 2
Left Crankcase Cover Stud Bolt 1 x 6 mm: 10 (1.0, 7) NOTE 1

Frame N-m (kgf-m, lbf-ft):
Sub-Frame Upper Mounting Nut 1 x 8 mm: 26 (2.7, 20)
Sub-Frame Lower Mounting Nut 2 x 8 mm: 42 (4.3, 31)
Exhaust Pipe Joint Nut 4 x 8 mm: 18 (1.8, 13)
Muffler Mounting Bolt 2 x 8 mm: 32 (3.3, 24)
Muffler Band Bolt 1 x 8 mm: 20 (2.0, 14)
Right Foot Peg Mounting Bolt 2 x 10 mm: 42 (4.3, 31)
Gearshift Pedal Pinch Bolt 1 x 6 mm: 12 (1.2, 9)
Front Axle Holder Nut 8 x 6 mm: 12 (1.2, 9)
Front Axle 1 x 16 mm: 88 (9.0, 65)
Front Brake Disc Bolt 4 x 6 mm: 20 (2.0, 14) NOTE 1
Front Rim Lock 1 x 8 mm: 13 (1.3, 9)
Fork Center Bolt 2 x 22 mm: 34 (3.5, 25) NOTE 1
Fork Cap 2 x 39 mm: 23 (2.3, 17)
Steering Stem Nut 1 x 24 mm: 98 (10.0, 72)
Rear Axle Nut 1 x 16 mm: 88 (9.0, 65)
Rear Brake Disc Bolt 4 x 8 mm: 42 (4.3, 31) NOTE 3
Driven Sprocket Bolt 6 x 8 mm: 32 (3.3, 24)
Rear Rim Lock Nut 1 x 8 mm: 13 (1.3, 9)
Shock Absorber Upper Mounting Nut 1 x 10 mm: 44 (4.5, 33)
Shock Absorber Lower Mounting Nut 1 x 10 mm: 44 (4.5, 33)
Shock Arm-to-Swingarm Nut 1 x 12 mm: 69 (7.0, 51)
Shock Link-to-Frame Nut 1 x 10 mm: 49 (5.0, 36)
Shock Link-to-Shock Arm Nut 1 x 10 mm: 44 (4.5, 33)
Swingarm Pivot Nut 1 x 14 mm: 88 (9.0, 65)
Chain Adjuster Stopper Pin 2 x 10 mm: 34 (3.5, 25) NOTE 1
Brake Hose Oil Bolt 4 x 10 mm: 34 (3.5, 25)
Pad Pin 2 x 10 mm: 18 (1.8, 13)
Pad Pin Plug 2 x 10 mm: 2.5 (0.25, 1.8 )
Caliper Bleed Valve 2 x 8 mm: 5.5 (0.55, 4.0)
Front Caliper Mounting Bolt 2 x 8 mm: 30 (3.1, 22) NOTE 3
Front Caliper Pin Bolt 1 x 8 mm: 23 (2.3, 17) NOTE 1
Front Caliper Bracket Pin Bolt 1 x 8 mm: 13 (1.3, 9) NOTE 1
Rear Caliper Pin Bolt 1 x 12 mm: 27 (2.8, 20)
Rear Caliper Bracket Pin Bolt 1 x 8 mm: 13 (1.3, 9) NOTE 1
Rear Master Cylinder Mounting Bolt 2 x 6 mm: 14 (1.4, 10) NOTE 3
Rear Master Cylinder Push Rod Lock Nut 1 x 8 mm: 18 (1.8, 13)
Side Stand Pivot Bolt 1 x 10 mm: 10 (1.0, 7) NOTE 5
Side Stand Pivot Nut 1 x 10 mm: 39 (4.0, 29)

NOTE 1: Apply locking agent to the threads.
NOTE 2: Apply oil to the threads and seating surface.
NOTE 3: ALOC bolt. Do not reuse.
NOTE 4: Stake.
NOTE 5: Loosen the bolt 1/8 turns to 1/4 turns after tightening it to the specified torque, then tighten the pivot nut.

[GregMember]

Flying Fish wrote:

So before I go get some proper graphic stickers to make this look a bit better, what do you think?
If somebody can come up with a better idea or style I will take it into consideration, no promises though………
Flying Fish

What about a bit of OBT sticker kit action made up in your colours to suit your bike off course, play with the design happy days Just an idea

Radiator Shrouds

Side panels

Front & Rear guards

TB

[GregMember]

Jeffro wrote:

mallee wrote:

Is there somewhere we can get a map of the route so I can see where you’s are going and what country at rally takes you through?
Also I may go over for a look and watch you guy’s go flying past :laugh:

Great shuff :cheer:

Mallee

See here Mallee
http://www.everytrail.com/view_trip.php?trip_id=1624670

Ummm Jeffro that’s only the two day ride I put together for Adv Moto to run a little practice
The 14 APC rally proper doesn’t really give a route out before hand

TB

[GregMember]

Ace and Eags I am pre running part of it this on Saturday but because I am going to the Cape am missing the actual ride :pinch:
I am doing the ride with a St Aburns start and finish, some extra changes and bits and bobs again in September date to be announced if you are interested.

Will be a Friday arvo arrival at St Aburns, camp across from the pub and go Saturday morning return Sunday arvo

TB

[GregMember]

Ace wrote:

Watch out for ‘Lovers Lane’ on the way. :whistle:

:laugh: :laugh: That was farking funny I can still hear Lenny pissing himself

TB

[GregMember]

Its nearly a 2000km drive to the start of this ride !!!!

TB

[Author]

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