Hi all, around 3 months ago I acquired a 1988 400WR in non running condition. The previous owner (personal friend) provided receipts for $2000 in engine work so I wasn't too concerned, and a look up the exhaust port did show a brand new piston, so the task began.
I think the only reason I ended up with it was because he was concerned that he may have needed to split the cases to rectify a gear shifting issue, despite my offers to do it for him.
Well that turned out to be a very simple fix, once the clutch cover came off, I noticed the return spring had been dislodged, easy.
What that also uncovered was the damage to the clutch basket, there is another topic here (
http://forum.ozvmx.com/index.php?topic=38686.msg373315#msg373315) about that so no need to repeat myself.
It took almost two months to find the clutch basket and it's now installed.
So the next step was having a good hard look at the bike to see what other surprises were in store.
I already knew the Ohlins shock needed a rebuild, so in to Suspension Smith in Canberra on Thursday morning, picked it up on Friday arvo, $220 including a new bump rubber, very reasonable I thought.
First up was the front brakes, not working at all, Magura master cylinder with Brembo caliper, after searching the interwebs I could find no conclusive info regarding a m/cyl kit or even a decent s/h m/cyl, then when removing the caliper, I found that the lower caliper bolt/pin is stripped.
After an hour or so with some aluminium plate on my mill, I'd made a caliper adapter and fitted a DRZ400 front wheel, axle and brakes until I can sort out the m/cyl and thread in the fork lower, are they magnesium?
The original exhaust was a bit beat up, so I bought a s/h "Uptite Racing" expansion chamber from Fleabay USA, which I'm told is the hot ticket for these engines.
It needs some "massaging" too, but I don't think it will need too much to have it looking like it belongs.
The PO had already done a fair bit of work, frame painted, seat rec0vered, two new tyres, new handlebars and levers (not Magura) so the list was noowhere near as long as it could have been.
After checking that my SEM ignition actually still produced a spark, a new plug, remove the treacle from the fuel tank, checked ignition timing, cleaned the gum out of the carb, two hearty kicks had it running like a champion, it even idles which surprised me.
Being dark I wasn't able to give it test ride, so I will wait until I do before I make any rash predictions!
I will be ordering some plastics and decal set for it and it should look great.
My plan with this bike is to use it in next years Vinduro events run by VTR, so I now have the summer to fettle the old girl and make sure it's as reliable as it can be.
Having previously owned an '86 400WR, my expectations are realistic, other than the rose coloured glasses when remembering my old bike. It really was a great bike though, great engine, great suspension, mediocre front disc brake, steered well and never let me down, not once.
Fingers crossed, hopefully is gets easier from here.....
Day one, just unloaded.
It was a bit dusty, but lots had been spent already, pitson, rings, conrod, mains, gearbox bearings, aluminium clutch cover instead of the old magnesium one.
Old clutch basket, damaged all the way around the ring gear.
Secondhand clutch in very good condition.
Caliper conversion, still needs a tidy up but it works, probably even a fair bit better than the original!
