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Old 05-03-2013, 09:17 AM   #5851
SpeedoJosh
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So pretty much, there would be no difference in a 98 to an 04 minus the red plastics?
Seems like the pre-2000s just look older.

Been scanning online, what's a good price for a tagged XR400?
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http://www.advrider.com/forums/showthread.php?t=754094
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Old 05-03-2013, 09:21 AM   #5852
Stretch67
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Pretty much, but there were a few subtle changes...

Clicky: http://www.thumpertalk.com/topic/152...6#entry1128656
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Old 05-03-2013, 01:20 PM   #5853
Clem Kevin
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Quote:
Originally Posted by Stretch67 View Post
This is incorrect. All XR400's share the same frame and subframe, which is detachable.
Dunno why I thought that, maybe I've seen too many pictures of xr600 frames?
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Old 05-03-2013, 02:57 PM   #5854
hughrk
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Quote:
Originally Posted by Clem Kevin View Post
Dunno why I thought that, maybe I've seen too many pictures of xr600 frames?
Or early xr250's? Later 250's share subframes with the 400.
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Old 05-03-2013, 08:31 PM   #5855
Stretch67
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Quote:
Originally Posted by hughrk View Post
Later 250's share subframes with the 400.
And many other things. The two are so similar that ThumperTalk lumps them both together...

http://www.thumpertalk.com/forum/18-xr250400/
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Old 05-05-2013, 02:40 PM   #5856
DREAMADVENTURER
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Location: Halkidiki, Greece
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Laugh Swingarm bolt from hell

Well i was hoping that my first post here would be about showing you my new to me XR400 1996 model but luck was never on my side..............
anyway i bought it 1 month ago and my purpose was to bring back to mint condition (plus the fact that im a mechanical engineer but i always told people how to fix staff but never layed a hand and i thought it was time to change that)
Anyway while checking it i realised that the front and back suspension was sugged (forgive my english) so i decided to take the bike apart fix and grease everything and while i was at it, paint the frame etc
so the nightmare began, i couldn take off the swingarm pivot bolt, i read everything on the net, i saw images i didnt want to see ( I still see nightmares about cutting the swingarm) I tried every possible solution, i loosened the engine supports, i raised the bike, i took off the rear suspension, i used heat, i used locktight freeze, wd40, penetrating oil
i used raw force..................nothing
i decided to drill it hopping it would break free or get loose but..............NOTHING
what i managed to do is break the head of the bolt loose but i still cant get any drill bigger than 10mm inside (I think its a matter of tools to be honest)
anyway in a moment of brilliance i decided to use a hacksaw (im not sure if this is how its called) and cut the bolt right next to the frame.....you know...right next to the dust cups.....which i did
Now what? i dont want to cut the swingarm and i dont have a room to use a circular saw, i tried with a dremel but the bushing is very hard the room is very tight and nothing
so here is my big idea and i want your opinion guys on that
As i said the bolt is free from the frame at both sides, so provided that the rear wheel is off and i remove the carburator and all the electrics from the frame if i remove the engine will i free also the swinarm with it?
i mean there is a pivot, if i take the engine off the right side of the frame and tilt it on its side, i think that the swingarm will clear the frame and because there is a pivot point i will be able to get it free
after that i will take the engine and swingarm to a machine shop and hopefully the will manage to release the engine and swingarm
so what do you think?
will it work?
anybody else has done something similar?
any opinions, experiences or ideas on the subject are welcome

DREAMADVENTURER screwed with this post 05-05-2013 at 03:40 PM
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Old 05-05-2013, 03:25 PM   #5857
MartiniUp
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Mechanical engineer? This is going to be interesting. Good luck.
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Old 05-05-2013, 03:42 PM   #5858
RSP
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XR Turn Signal Kit



Anyone have any suggestions on turn signal kits for an 88 XR250?
i.e. places to buy, best deals, and is it worth the trouble/money?
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Old 05-05-2013, 03:43 PM   #5859
DrLewall
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Quote:
Originally Posted by DREAMADVENTURER View Post
so the nightmare began, i couldn take off the swingarm pivot bolt, i read everything on the net, i saw images i didnt want to see ( I still see nightmares about cutting the swingarm)
Meh....been there and done that!

it's tough enough to get the motor out of the frame as it is, let alone with the swing arm still attached. I believe you will be in for a major wrestling match and you will probably make up some new cuss words..BUT, it is worth a try anyway.

Give it a go, take some pictures, and post back here on how it's going..worst case scenerio, you can always cut the swing arm off...
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Old 05-05-2013, 04:31 PM   #5860
Stretch67
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Quote:
Originally Posted by RSP View Post


Anyone have any suggestions on turn signal kits for an 88 XR250?
i.e. places to buy, best deals, and is it worth the trouble/money?
It's not impossible, just may take a bit of fabricating to make it all fit... a flasher, the turn signals themselves and fabricating mounts for them, running the wires.

http://www.procycle.us/dskits/dskit.htm#turnsignals

Check your PMs, by the way.
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Old 05-05-2013, 06:10 PM   #5861
Ed@Ford
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Joined: Jan 2004
Location: Dearborn MI
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Wicked

Quote:
Originally Posted by DREAMADVENTURER View Post
Well i was hoping that my first post here would be about showing you my new to me XR400 1996 model but luck was never on my side..............
anyway i bought it 1 month ago and my purpose was to bring back to mint condition (plus the fact that im a mechanical engineer but i always told people how to fix staff but never layed a hand and i thought it was time to change that)
Anyway while checking it i realised that the front and back suspension was sugged (forgive my english) so i decided to take the bike apart fix and grease everything and while i was at it, paint the frame etc
so the nightmare began, i couldn take off the swingarm pivot bolt, i read everything on the net, i saw images i didnt want to see ( I still see nightmares about cutting the swingarm) I tried every possible solution, i loosened the engine supports, i raised the bike, i took off the rear suspension, i used heat, i used locktight freeze, wd40, penetrating oil
i used raw force..................nothing
i decided to drill it hopping it would break free or get loose but..............NOTHING
what i managed to do is break the head of the bolt loose but i still cant get any drill bigger than 10mm inside (I think its a matter of tools to be honest)
anyway in a moment of brilliance i decided to use a hacksaw (im not sure if this is how its called) and cut the bolt right next to the frame.....you know...right next to the dust cups.....which i did
Now what? i dont want to cut the swingarm and i dont have a room to use a circular saw, i tried with a dremel but the bushing is very hard the room is very tight and nothing
so here is my big idea and i want your opinion guys on that
As i said the bolt is free from the frame at both sides, so provided that the rear wheel is off and i remove the carburator and all the electrics from the frame if i remove the engine will i free also the swinarm with it?
i mean there is a pivot, if i take the engine off the right side of the frame and tilt it on its side, i think that the swingarm will clear the frame and because there is a pivot point i will be able to get it free
after that i will take the engine and swingarm to a machine shop and hopefully the will manage to release the engine and swingarm
so what do you think?
will it work?
anybody else has done something similar?
any opinions, experiences or ideas on the subject are welcome
Dr. Lewall has a link dedicated to how he solved the exact problem you have. It's listed somewhere in this XR400 posting...start searching.

I solved mine differently by drilling out the swing arm bolt in very tiny steps to free the engine + swing arm from the frame. The swing arm bolt is soft....the bushings in the swing arm are EXTREMELY hard....and are not drillable. It is possible to get the engine+swing arm out of the frame...but is very tricky. Then the swing arm must be cut to bits to get all that off the engine. Then the hardened bushings can be split with a die grinder...this will leave the reminants of the swing arm bolt rusted into the steel bushing in the rear of the engine....at least that's how mine was. Then with lotsa heat, penetrating oil, twisting and pounding I got the swing arm bolt loosened up and was able to pound it out. I spent several days at it.
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Old 05-05-2013, 06:37 PM   #5862
Stretch67
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Quote:
Originally Posted by Ed@Ford View Post
Dr. Lewall has a link dedicated to how he solved the exact problem you have.
http://www.advrider.com/forums/showthread.php?t=532835
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Old 05-06-2013, 12:08 AM   #5863
DrLewall
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Quote:
Originally Posted by Stretch67 View Post
Oh thanks alot for making me re-live that night mare!


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Old 05-06-2013, 02:54 AM   #5864
FSRIDER
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My new 2003 XR400

I bought this bike in October to replace my 2008 DR650. I fitted it with a dual sport kit last month and have been enjoying it ever since. I always like to brows pictures of all the bikes on this forum so I thought I would share mine as well.






Its been a great bike so far, I put some new plastics and a 4gal IMS tank recently as you can see from the last couple pics. I'm looking forward to some serious dual sporting this summer!
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Old 05-06-2013, 09:14 AM   #5865
KilLeR Kawasaki
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Your pics aren't showing, but congrats anyways!
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