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Old 05-06-2013, 09:33 AM   #5866
aaron2a
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Joined: Feb 2013
Location: canton, ms
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Anyone know where I can get an electric start kit or at least the crankshaft extension?
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Old 05-06-2013, 05:57 PM   #5867
Stretch67
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Location: Bent, but not broken
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Quote:
Originally Posted by DrLewall View Post
Oh thanks alot for making me re-live that night mare!


Madness takes its toll... please have exact change.
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Old 05-06-2013, 06:07 PM   #5868
hughrk
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Location: Scotland
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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
You are on the right track, drill out both ends of the bolt then take the engine and swing arm assy out of the frame.
Once on the ground you can put a socket under the pivot, block the swingarm and engine then swing a BIG hammer at that bolt, and I mean BIG.
You are aiming to move the bolt the width of a hacksaw blade, this will allow you to insert a hacksaw blade between the bush in the casing and the bearing bush. You will have to insert the blade then connect the tool frame at a 90 degree from normal angle. Turn over the assy and repeat, job almost done. Just the bit of bolt left in the casing which is easy, one of the bush's will probably come out with the bit of bolt, just split them in a vice.

If you get really, really stuck then cut up your swingarm but its probably not required.

Thats how this Mechanical Engineer did it
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Old 05-06-2013, 06:12 PM   #5869
Stretch67
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All this so Honda could save three cents worth of grease per bike.
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Old 05-06-2013, 11:56 PM   #5870
FSRIDER
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Location: Washington
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OK let's try these pictures again...


FSRIDER screwed with this post 05-07-2013 at 12:15 AM
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Old 05-07-2013, 12:16 AM   #5871
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Old 05-07-2013, 12:18 AM   #5872
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Old 05-07-2013, 12:18 AM   #5873
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Old 05-07-2013, 12:27 AM   #5874
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Old 05-07-2013, 02:20 AM   #5875
TARider
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Joined: Dec 2004
Location: Santa Barbara
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XR400 E-Start

Quote:
Originally Posted by aaron2a View Post
Anyone know where I can get an electric start kit or at least the crankshaft extension?
I bought extension from Boechat. http://www.boechat.ch/fr/p4-4113.html
Almost everything else I bought used through ebay. Most of Honda atv 400ex parts work for conversion. Some machining needed to done on starter ring in order to fit appropiate bearings. I may have manual copy scanned somewhere. PM if you need it.
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Old 05-07-2013, 02:43 AM   #5876
FSRIDER
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XR400 estart

How much does it cost to convert to estart?
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Old 05-07-2013, 02:58 AM   #5877
DrLewall
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Originally Posted by fsryder View Post
How much does it cost to convert to estart?
last time I checked, was around $1400..I think that was for a kit that was available a few years ago..If I remember right that is
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Old 05-07-2013, 03:29 AM   #5878
FSRIDER
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Eek

OUCH! I think I will just keep kicking mine over.
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Old 05-07-2013, 05:01 AM   #5879
RideFreak
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Location: County Lockup, NM
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Originally Posted by hughrk View Post

Thats how this Mechanical Engineer did it
I'm just a lowly technician w/o the benefit from years of schooling but I'd press the bolt out using some heat and a hydraulic shop press. I like to avoid the BFH at all costs, it's never pretty.
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Old 05-07-2013, 05:29 AM   #5880
hughrk
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Quote:
Originally Posted by RideFreak View Post
I'm just a lowly technician w/o the benefit from years of schooling but I'd press the bolt out using some heat and a hydraulic shop press. I like to avoid the BFH at all costs, it's never pretty.
So would I but if you dont have that sort of a workshop available to you then BFH it is.
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