Project on Hold

The XR400GP Project is on hold for the time being. Why? I found a really good deal on a 1994 Yamaha TZ125! While I am sure the XR/GP bike will prove far more cost effective for track days, the TZ should be more immediately ready to ride.

Short hiatus

Just wanted to post an update that there haven't been any updates for a while. It's been raining cats and dogs here in Pittsburgh pretty much ever since the snow quit, plus I've been real busy with work. I have gotten in some parts to rebuild the XR's top end, and need to pull the carb off to see what it needs. Hoping to post some more progress soon.

Well, actually there is some progress. I measured up the distance between the triple clamps on the GSXR front end and the disance between the XR's triples, and it's less than a half inch of difference. That's a good sign. My next step is to take some geometry measurements on the stock bike and then make a model of how the geometry will end up once the GSXR front end is grafted on, to see if I'm close to where I want it to be. 

XR test ride

Fired up the XR today and rode around the yard a little, to get an idea what needs to be done to the motor. Definitely needs a carb rebuild -- the choke lever no longer stays up on its own, and the drain screw doesn't seal up, so it leaks gas the whole time the petcock is open. Besides that, the engine smokes a bit at startup, so it probably needs valve seals, and I can hear some ticking from the head, so the valves probably need some adjustment, and possibly a valve job.

I ordered a top end gasket kit last week, so as soon as it comes in, I can start tearing into it. Looks like I need to order a carb rebuild kit, too.

On the upside, holy cow is this bike a wheelie machine. I wasn't used to the clutch from having not ridden this bike in a few years, and wheelied the entire length of my driveway on the first launch. Can't wait to see how it acts with a fresh top end and carb!

XR photo

A quick photo of the XR as it now sits in my garage. My garage is pretty cluttered up at the moment, so I blurred out the mess in the background.

As you can see from the Baja Designs headlight, I once had good intentions of making my XR into a dualsport. It has a horn and used to have turn signals and brake light as well, but I never quite got around to filing all the paperwork. I still have all the street goodies, so it's possible that once the bike is transformed into a GP/track day bike, it may yet become street legal in the future.

As I suspected, the header bolts are pretty well rusted up, so I have begun soaking them in Aerokroil.

Parts order

My 1996 XR400 smokes a bit when first started, so the motor most likely needs some new valve seals, and possibly rings. Since I want to check the valves and rings anyway, I ordered a top-end gasket kit and exhaust gaskets yesterday.

I'm not looking forward to unbolting the exhaust. It's been on the bike since new, and I'm sure getting the header bolts out is going to be a pain. Hmmm.... Maybe I should go soak them in Aerokroil tonight before bed.

New Logo

I made up a new logo for the site; might have to get it made into stickers for the bike!

Pics

Original XR frame geometry

Slide the stock forks up in the clamps, and lower rear ride height

Swap out front end for GSXR front end

Show seat and gas tank

Add bodywork

Add tail section

Some concept pics. Created by tracing over a photo of the stock XR400 frame, then modifying in a drawing program.

2007 GSXR 600 Complete Front End

GSXR Front end I bought used. I also picked up a '93 Katana 600 rear wheel.