Xr400 - The rebuild

[Richywrecka]

Right o here goes then.

I got my hands on my brothers Xr400 that has been sitting around not being abused as it should be.
Its been off road for the last 2 - 3 years and was in quite a state.

This is how i received the bike


So out came the spanners and i got stuck in stripping the wee beasty down



Ended up with bits of Xr all over my garage....





and so the fun started. had to cut the swinging arm out as the bolt had seized solid to the bearings, that was fun, all the lower link bearings were crunchy, and the top shock bearing, the head stock bearing as well, the forks leaked, the engine leaked oil, so i thought, what have i done........

So i painted the frame......get the easy bit done first



Rebuilt the top end of the engine as i know the bottom end is alright as i've had the bike running ok before stripping it down



Oil leak on that now cured due to a missing base gasket on the barrel. now we start on the carb, which was in a very state of repair, cleaned it ,serviced all the serviceable parts, and had to make a new choke butterfly as the old one had been destroyed by i dont want to know



heres the new and old butterfly, guess which is which.....



and so the bolts start going in and it start taking the shape of an Xr again


i stopped with the camera now for a while because i started swearing to much and was unable to take pictures ( i might have thrown the camera thinking it was a spanner )

still bits arrived for it daily with the question being raised by my wife " just how much have you spent on that bloody bike ?? "

Erm...................no comment

well a quick list of new parts fitted, start at the front and i might remember them all,

new front wheel bearings, new fork and dust seals, new fork gaiters, new front pads, new head stock bearings, new hand guards and new grips, engine top end rebuild, all new fuel lines, carb rebuilt, swinging arm bearings, lower link bearings, top shock bearing, rear wheel bearings, new chain.
theres more but i cant remember, the front and rear calipers have been rebuilt as well, nice new Trelleborg Army Special tyres fitted, and they look sweet





there has been lots of cleaning and lubricating of parts various, theres a couple of silly jobs left but there about 30 mins work and thats it finished. it runs it moves it stops, nice. now just got to stick it through its MOT, stick some rent on it and then fall off it lots while grinning......cant bloody wait

heres the finished article, sitting in the glorious sunshine, before i get down and dirty with it......

[jasonbc]

Thats a damn fine job done there, just out of curiosity why did you paint the frame white?

[Richywrecka]

Thanks for that, I am pleased with way it looks and rides now. As to why did I paint the frame White............I don't know really, just thought it would be a be different, nice and individual I suppose

[axbol]

top job matey . where did you get the tyres from, they do look sweet..

[axbol]

top job matey.
where did the tyres come from, they do look sweet, wouldn't mind some
cheerio

[Richywrecka]

Hello mate, the tyres are Trelleborg Army Specials. As used by the Swedish army, the web site says there road legal as well and has some good write ups about them. They have the E mark on them.

I got mine from Trellesport, google that one. Thought they were a bargain as well £100 for the pair delivered to my door.

[phil w]

Looks a good re fresh... not sure about the swing arm being white as well. Good service from Trellesport

[Neilios]

Very nice job mate, good to keep these old bikes going, just go my next project!!

[Longman]

Good looking bike, I like the XR400, nice work.

[Richywrecka]

Thank you people, just can't wait to get out on it now, bloody dvla are dragging there heals a bit with the log book.
Looking at getting on the road for the 1st July.

I am itching to ride it but had to lock it away so I'm not tempted