Completed rebuild

[taggkent]

Hi all, id just like to have a little boast about my finished XR restoration (ok, so its only a 01 model maybe restoration is a bit strong)
Heres what ive done;

77mm piston giving 277cc (WEISCO)
Intake and exhaust ports smoothed and matched to manifolds,
Stainless steel racing exhaust (CRD),
Duel type foam air filter (Twinair) and high flow airbox cage,
Extra wide foot pegs,
wireless digital speedo,
Aluminium bash plate,
Magnetic sump and oil reservoir plugs,
Shotblast and Powder coated frame,
New valve springs,New intake valves, Heavy duty clutch springs (ECB) New cam chain (DID) New cam chain tensioner, New cam chain guide,
New O ring chain and sprocket set (stock sprocket sizes) (Izumi), New chain slider (OEM)
Complete rewire to accomodate 12V Nihm 10 cell battery, headlight, full beam, stoplight, horn and number plate light
Complete engine overhaul and refit including various bottom end bearing etc,
Removed manual decompressor and added aluminium insert to hole in cylinder head,
New front brake pads, New stainless steel brake pistons and new seals,
Removed speedo assembly, and made up stainless steel spacer and insert to accomodate normal bearing seal.
New front wheel bearings and seals, New rear wheel bearings and seals,
Complete Rear suspension and linkage rebuild (new bushes and bearings),
Complete front Fork service including; MXW Racing fork springs (stiffer), new bushes, seals and fork oil, I also removed 3 of the 7 shims in the compression stack for lighter high speed compression damping
Wrap around hand guards, Homemade Bar risers and long reachers
Homemade headlight bracket to give me room for all the bloody cables an wires hehe.
Homemade numberplate bracket and LED numberplate light.

Thats where I am to date, shees waiting for the MOT on friday (hopefully itl pass)

If anyone is planning to do anything i have done, feel free to ask me for info

Anyway heres the pic;


I have plenty of other pics i can upload if any1 is interested in anythin in particular.

[phil w]

Nice job bet it pulls well the 280 seems to be a popular thing to do and seeing one on the trails of a mate they certainly do not struggle. Like the CRD exhaust , a friend had one on his 400 last week and it was a nicer sound than standard without being loud

[taggkent]

yea ive only been on a quick spin but definately seems to have more grunt, mind you i have gone up a tooth on the rear and cleaned up the ports so i dunno how much can be attributed to each change.

Yea CRD exhaust does sound good, a bit of a bark to it but not TOO loud to put up with. Unlike my mates xr400 who i cant even ride behind without earplugs heh

[xrvirgin]

lets see some of your pics then laddie

[Kes]

I went the other way on the gearing as 75% is on the mileage road ( 800 since March) 14/45 .
1st gear still only last 5yds Lol!!

[ogri]

nice one,wish you many happy hours of ownership.you may live to regret removing the manual decomp though.cleaning it out after an off just doesn't seem to work as well without it.a small matter though.love to have a go on it.

[taggkent]

What pics would you like to see?

Yea shame about the decomp, il just try not to fall off i spose

Cheers Ogri, Im considering a trip to south wales so you might just get a chance!

My fork seals are still leaking (brand new AllBalls ones) i can only guess i installed them wrong. Ive ordered some OEM and they should arrive tommorrow so il be more carefull this time hehe.

Well impressed with the forks appart from the leaks tho, I fully recommend the shim stack mod / a good fork service / getting the right springs for your weight. But I dont know how much difference each change made on its own.

[kempouk]

nice job,
did you paint the tank or is that just cleaned?
looks a real nice machine though well done.

[taggkent]

yea the tank came up really well, what i did was;

Emptied the tank and made sure there was NO vapour left in it

got all the glue and crap off it with solvents

then used a heat gun (you know the type used for shrinking heat shrink on etc) to heat up the surface till it melted ever so slightly and went shiney!

took about 15 mins to do the whole thing and it came up lovely!

Kindo of worked for the other plastics, but not as well cause its made of a different type of plastic

Trouble is the seat looks really ****ty, i might get one of those black gripper seat covers and redo it (make it a bit less square too cause it hurts after a few hours hehe)

[kempouk]

what a good idea with the heat gun, i painted mine and it just isn't the same, i work with a lister heat gun as well so i might try that out as it looks nice and clean.
did it take out the scratches as well ?
i guess it would do as it is melting the top layer back to its original condition.
did you use anything to buff it or just the heat from the gun ?