xr 400 kickstar conversion ?

[hybridracer686]

i was going over some pics of xr 400s and noticed that the bikes are kick start. and got to thinking about trying the conversion on my ex. question is has it been done and will the foot peg just get in the way of the stroke when kicked. the outside case would have to be replaced but will the inner case need to be changed as well just a thought:confused:

[DnB_racing]

it was a hot topic a couple years ago... and the end results are yes you can do it, as long as its a model without reverse

http://www.exriders.com/vbb/showthread.php?s=&threadid=293068&perpage=13&highlight=kickstart&pagenumber=1

[powerbomb400]

The hole is still in the casting its would have to be drilled out. I wish they didn't make the case to where you have to take the whole side off just to get to the clutch basket. I have an 05 thats how I know.

[bkb88]

I have recently made the swap with the XR400 side case and clutch cover. I did have the kick starter hole welded shut however. I made a list of parts that must be used if you are planning on using the stock XR clutch cover. I would assume all that would be needed after that would be: stock XR400 clutch basket (with extra gear for kick start), complete kick starter assembly, and a modified brake lever to clear the kick starter.

Here (http://www.exriders.com/vbb/showthread.php?s=&threadid=472539) is the link to the thread.

[fauxamish]

My bike is kickstart. The stock foot peg does get in the way. I solved this by basically pro-pegging it with some some custom brackets and an old set of nerfs. You also need to make a custom brake petal that goes under the footpeg.

I eliminated the electric start all together, and its worth it if you race. It sucks kicking it when its cold, but its not too bad.

[hybridracer686]

thanks for the info im considering doing this to my 400. its an 02 so no reverse on it. any pics of the modifications made to the peg or brake lever for referance would be cool thanks again.

[fauxamish]

I don't have any pics right now cause the bike is in Ohio and I'm stationed in Texas for another 3 weeks. I'll get some when I get home though.

[426kidz]

hardest part is goin to be able to find a hinson clutch cover for it...if you do its gonna cost ya!:(

[hybridracer686]

interesting to know. have to keep an eye out on ebay i guess for the parts. plan to start the conversion when i get the last few items to finish the bike. chain, sprockets, stage 2 hot cam, battery, and axel carrier. again thanks for the help and links.

[426kidz]

yeah you need a hisnon cover sense the 400ex basket and clutch are widder the xr wont work right if im not mistaken:D good luck

[fauxamish]

You need the gear plate off the back of the clutch basket from the XR400. I just used the complete XR400 clutch which isn't as thick as the 400ex clutch. I think you could also machine the inside of the XR400 cover for the 400ex clutch to fit.

[bkb88]

Originally posted by 426kidz
yeah you need a hisnon cover sense the 400ex basket and clutch are widder the xr wont work right if im not mistaken:D good luck

Look at my posted link at the beginning of this thread. No need to run a Hinson cover. Also, they can be purchased from Hinson for around $200 if I'm not mistaken.