STRIP ENGINE PROJECT

Inspection procrdures

1. Check block/piston/piston ring clearance

a. All okay!
b. No scouring on piston and block.
c. No cylinder wear visible.
d. Likely piston ring installation incorrect. Replace piston ring. Straight on top, tapered
below, place hole away from each other. ANYWAY DO PISTON CHECKS AGAIN AS
PER XR400 MANUAL PAGE 8-3
e. If you only put new rings in it then that is the source of the problem. When the engine
wears the cylinder and rings wear together. The cylinder wears in an oval pattern on
the front and back. New rings will not seal on a cylinder that is no longer round. The
correct way to fix it is to bore the cylinder to the next oversize so that it is once again
round and install the corresponding oversize piston and rings.

2. Check for piston blow-by for oil stains

a. No signs of blowby oil stains, therefore not cylinder worn.
3. Check valve clearance when fully closed using [petrol/diesel leak check]
If leaking a) decoke valves and b) replace valve guide seals.
4. Check valve guides for wear
5. Check valve spring clearance
6. Check camchain length
7. Check for wears or signs of breakage on counter shaft at bushing side. If yes, buy 1999
otherwise buy 1998 if significantly economical.
8. Add washer on top of clutch springs to improve compression.
9. Check crankcase cracked area, see if any more cracks, if yes, please patch.

http://www.xrv.org.uk/forums/xr/80529-run-no-oil.html No oil

http://www.thumpertalk.com/topic/781071-idler-gear-up-against-the-case/ Counter shaft crack at

idler gear

http://www.cheapcycleparts.com/model_years/870-honda-1998-xr400r/assemblies/12124-cylinder

http://www.cheapcycleparts.com/model_years/926-honda-1999-xr400r/assemblies/12124-cylinder

For picture references

Procurement

Item S/N. Cost Comments

Crank Case
Gasket-split crankcase-clutch 11394-KCY-671 Cyclepart: $13.05
Gasket split crankcase-cyl 11191-KCY-670 Cyclepart: $18.26

Sprocket Oil Seal (18X29X7) 91202-KK0-003 Cyclepart: $5.97 Check cond.

*Sprocket counter shaft (1999) 23220-KCY-671 Cyclepart: $86.09 Optional, check if the
CA: $180 above ext’g is worn or
damaged.
Sub: Countershaft idler gear bushing 28222-kk0-000 Cyclepart: $21.63 Optional, will require if buying
(15mm) to meet new 1999 CS CA: $18 1999 CS
(1998 model is 14mm)
Sub: Washer (18mm) 90452-701-000 Cyclepart: $1.60 Optional, will require if buying
CA: Don’t sell 1999 CS
Sub: Bearing Cyclepart: $13.48 Optional, will require if buying
91004-kcy-761 CA: $17 1999 CS
Sub: Oil Seal 91204-kcy-672 Cyclepart: $4.23 Optional, will require if buying
CA: $5.50 1999 CS
*Sprocket counter shaft (1998) 23220-KCY-670 Cyclepart: $115.91 Check if the above
CA: don’t sell. assembly is cheaper.
Kick Starter Oil Seal 91204-KCY-671 Cyclepart: $5.67 Check cond.
(17X34X4.5)
Gear shifter pedal (new, TBC) 24700-KCY-A10 Cyclepart: $35
Gear shifter oil seal (14X28X7) 91202-965-003 Cyclepart: $4.78
Clutch puller oil seal (12X18X5) 91204-KK0-003 Cyclepart $3.77 Check cond.
Clutch case 11350-KCY-670 Cyclepart: $68
Clutch springs x 4 x 2sets 22401-MM9-000 Cyclepart: $4 x 2
CA: $4.50/spring
Gasket/oilseal for clutch case 91311-KCY-670 Cyclepart: $7.28
Oil filter Oil seal (54X2.4) 91302-KF0-003 Cyclepart: $3.10 Check cond
Oil seal, alternator cover big 91305-KF0-003 Cycle part: $2.76
Extra oil filters! X 3 K&N $5 x 3
*Clutch basket wiseco Wiseco $256 Need spring caps,
provided can find
spring caps. This will
last very long.
*Clutch basket stock w/ gear 22100-KCY-670 Cyclepart: $201.40 All brand new. Maybe
set last 6 years.
Swingarm pivot bolt 90121-KAE-000 Cyclepart: $36.78
Swingarm pivot bolt U-nut 90305-GE8-003 Cyclepart: $3.48
14mm
Swingarm pivot bolt bearing 91106-KF0-008 Cyclepart: $17.65
(20X26X12)
Swingarm pivot bolt bear. Seal 91254-KS6-003 Cyclepart: $6.62
(20X26X4.5)
Cylinder Block
Gasket, below Cylinder Block 12191-KCY-672 Cyclepart: $7.74
O ring, below Cylinder Block 91302-356-000 Cyclepart: $6.53
(88x2)
Cylinder Head
Gasket, below Cylinder Head 12251-MBV-013 Cyclepart: $15.58
Valve guide x 4 on cyl. head 12231-KF0-305 Cyclepart: $14.50 Check cond.
O-Ring (10x1.6) 91301-200-000 Cyclepart: $2.99 CHANGE!
Valve guide seal o-ring x 4
Valve stem seal x 4 (NOK) 12209-KL4-005 Cyclepart: $5.82
O-Ring (45x2.5) 91303-397-000 Cyclepart: $3.52 CHANGE
Air intake o-ring
Cylinder Head Cover
Gasket, below Cylinder Head 12391-KCY-671 Cyclepart: $31.12
Cover
Oil Seal (tappet valve cap) x2x2 91301-428-003 Cyclepart: $2.57 x 2 Check cond.
SUB TOTAL ABOVE $318
Piston
Piston Kit Wiseco 86mm 11:1 Piston set/ with gasket $150 / $240 Check what gasket is
provided, if less gasket
or more exp, buy stock
from dealer.
Misc
Y-tube for aloop tank --- Cheap Or plug right side.
Suspension servicing --- $280 Check manual 1st.

Extra
Clutch cable DRZ400 S30
Clutch cable XR400 S30
Speedo Cable XR400 S30

a) Block/Piston
b) Misc.
c) Hidayat’s extra