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Old 01-08-2011, 05:59 PM   #1
booger1 OP
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Joined: Mar 2010
Location: Arizona
Oddometer: 815
1998 xr400 build

Yearlier this year I was in Baja, A trip I've been wanting to do since I was was 10 yrs old after hearing and seeing pictures of the Baja 1000. I'm now 37 and was getting the chance to go.
Long story short, The bike was running awsome, a little smoke on start up but goes away, typical of the old xr's (old valve guides).
But really it ran awsome, usually 1 or 2 kicks to start in the mornings and even after crashing.
Well 4 days in to the trip,




That's the bearing for the counter balance shaft.
Some extra carnage.






I know this doesn't typicaly happen on xr's, but to it's defense, I've had her for about 8yrs now and numerous topends in various configerations from bone stock to 440 power, This thing would top out at 98mph (per my GPS).
Luckily I got back, thanks to my girlfriend coming down to get me.
And I wanted to do something differant with the bike than most ppl would do, make it electric start.
I was already planning on this for awhile now.
Found an ex400 bottem end on craigslist for $100 and a wiring harness for also $100 a few yrs back, so all is sitting in my little garage when I got back.
Someone had said that the motor was not a direct fit. This would be a show stopper, so I cleaned up the engine cases and put it in.

It's close, but the bottem front mount does appear to be off, but the counter sprocket shaft looks good to continue.
Now I also wanted to do something else with this thing, because I can, Give it a kick start as well. Know I'll have 3 ways of starting this thing. 1 .electric, because I'm getting old and lazy, 2. kick if the battery dies and if that happens 3. push start.
I ended up talking to another ADV inmate (forgot his name, sorry) one day, because he had done this and said he hard a hard time getting the E-start reliable, but once he did he said it was all worth the trouble.
So I'm on a mission now, I have the whole bottem end of the ex motor and various parts to the xr. I found be using the counter sprocket shaft from the xr (replaced 3yrs ago, should be good) and putting all the ex transmission gears on that shaft would allow me to put the kick start gear on.





This bushing will go on the xr shaft to allow the gear to go on, I suppose if you had the means you could have the ex shaft milled down, but I have the shaft, bushing, and gear.
And it goes on like this.

and will look like this once all is in place.
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Old 01-08-2011, 06:26 PM   #2
booger1 OP
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Building motors is fun for me, been doing it for many yrs and it just plane relaxs me. If it's not broke, I have to figure out away to fix it.
I was going to document prices for this whole build, but I didn't write anything down when starting to purchase this stuff, but I do remeber everything that went into it.
First was the weisco crank and rod. Pricey at about $300 but it's heavy duty and I don't want to take a chance on running old parts at this point.
I've heard great things about JE pistons and since I've always used wiesco I thought I'd give it try. I can't remember how much more it was but I do know it was more money than the wiesco's.
Just so you know, I went back to the stock 398cc's but raised the compression to 10.5-1.
I was suprised to see a spec sheet that came with the piston, showing measurments and weight. Already a plus, not that it makes much difference, looking at the piston it does appear to be better quality. But I'll find out after a year or so riding if it is better.
I had also heard about using a crf450 cam chain, they say it's cheaper, but I don't really care about that, I like the idea that it's stronger.


It's starting to take shape.
As I stated before about the vavle guides going bad.
All new kibble white stuff in here. The parts were around $200 to $250, but the sticker shock came out the machine shop installing them $350 .


But they look nice in there.
I had already ported the head awhile back.
D-shaping the exhaust ports.


Cleaned up the intake. This use to be nice and shiny but they used glassbead to clean them up.
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Eating_goat_with_the_Cartel , Never_ventured_never_gained
oncostaricantime , boundlessbooger , 1998xr400buildwithe-start
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booger1 screwed with this post 01-09-2011 at 08:01 AM
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Old 01-08-2011, 07:39 PM   #3
mcma111
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The engine work is looking good.

Since you have it this far apart how about getting the frame powder coated? Send the kickstand and any other parts you need spiffed up.
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Old 01-08-2011, 08:56 PM   #4
booger1 OP
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I did think about the powder coating thing, but it's a dirtbike, I'm only planning on painting where I welded.
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Old 01-09-2011, 06:24 AM   #5
RideFreak
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Booger, thanks for the pics and writeup, I've been toying with the same idea, TRX bottom end swap w/ kick start. I heard the same thing, that it didn't fit. If all that's different is the fr mm that's not a show stopper for me at all. Did you get the EX stator also, the charging system should be a breeze w/ that. I see no issues with making the charging/starting system just as reliable as the EX, it's going to take a decent battery though, KTMs been doing it with the RFS models for years with a small battery. The XR4 airbox w/ the top removed looks like you could fit a KTM sized battery and solenoid suspended in there just like they do on the RFS models, should be an easy bracket fab. The PO cut the top out of my XR4's airbox and it's not been an issue in deep water nor NMs dusty desert conditions with a twin air filter. PM me if you end up making your own harness and need any info/ideas, I've built a few for some XRs that worked out pretty well and got some diagrams that may help you out.
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"Life's journey is not to arrive at the grave safely in a well preserved body, but to rather skid in sideways, totally worn out, shouting ... Holy Shit, what a ride!"
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Old 01-09-2011, 06:42 AM   #6
booger1 OP
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Ridefreak, I'm getting to that stuff. As for the battery in the airbox, I decided that I would just build a box for the subframe like on the xr650l. I know alot of ppl put it in the airbox but, I kinda of want to make it look all stock, as if Honda built it that way.
I, like your self had been looking all over the internet for some kind of write up on doing this, I saw alot of pics and video's, but no discreption of how it was done.
I should also state that the ex engine is out of a 2000 model quad. I'm not sure if they all are built alike.
I now that there were some differances between the 98 xr and 99 xr. That counter sprocket shaft is the one differance I found out 3 yrs ago. The 99 shaft is 1mm thicker, I guess that's why mine had broke, but I was running close to 13-1 compresssion.
as this write up goes on I may look you up for help on the wiring, that's my weak spot, I jsut don't have enough experiance with that, Thanks in advance for your help that I may need.
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Old 10-06-2014, 12:05 PM   #7
CaboBound
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1998 Honda XR 400 - need a kickstarter

Great job on the rebuild Booger1.

I'm also about to take my bike down the baja, but my kickstarter just snapped in half. Every time I order a piece online, I get an email a few days later saying that part is no longer available. Here is the part number for the kick starter:

28300-KCY-760

Anybody have an idea how I can find this?!? I'll be in San Diego for the next few days - there has to be a good Motorsport parts shop down there, right!?

Appreciate the help.
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Old 10-06-2014, 01:43 PM   #8
DrLewall
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Quote:
Originally Posted by CaboBound View Post
Great job on the rebuild Booger1.

I'm also about to take my bike down the baja, but my kickstarter just snapped in half. Every time I order a piece online, I get an email a few days later saying that part is no longer available. Here is the part number for the kick starter:

28300-KCY-760

Anybody have an idea how I can find this?!? I'll be in San Diego for the next few days - there has to be a good Motorsport parts shop down there, right!?

Appreciate the help.
swap out the last 3 numbers from 760 to 670...found one here!

The last time I bought one, I bitched abt the $95 price tag..now they are $122......holieee cheeit!
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Old 10-06-2014, 06:28 PM   #9
MartiniUp
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Quote:
Originally Posted by DrLewall View Post
swap out the last 3 numbers from 760 to 670...found one here!

The last time I bought one, I bitched abt the $95 price tag..now they are $122......holieee cheeit!
$76.15 at Honda East Toledo. Partzilla is bogus.
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Old 10-06-2014, 06:48 PM   #10
DrLewall
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Originally Posted by MartiniUp View Post
$76.15 at Honda East Toledo. Partzilla is bogus.
Gawd I wish I was better with searches!

Good find Martiniweeny
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Old 10-06-2014, 11:49 PM   #11
CaboBound
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Thumb

Quote:
Originally Posted by DrLewall View Post
swap out the last 3 numbers from 760 to 670...found one here!

The last time I bought one, I bitched abt the $95 price tag..now they are $122......holieee cheeit!
You are awesome DrLewall! Appreciate the help!
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Old 10-07-2014, 12:02 PM   #12
MartiniUp
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Old 10-07-2014, 12:12 PM   #13
booger1 OP
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Looks like DRlewall has go you covered, make sure you get the right year as well, not all the parts are interchangeable between years.
Keeps us posted on your trip.


I did sell the bike a few months ago to a guy that really needed this bike. I'm very happy it went to a good home. I do still see her and get to ride along side. Just letting everyone know it did change hands.
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