Author Topic: 400/4 Restoration (Read 3428 times)

ComfySofa · « **on:** February 16, 2020, 06:52:01 AM »

Not sure where my other post went but, i guess it was in the wrong place. Started last week (took the day on saturday to get it down to the frame....just in the middle of looking for the initial strip down photos...this is it 6 years ago before it went into storage...it wasnt too bad then but, 6 years in a damp shipping container cemented the fact it needed to be stripped.

scrambler · « **Reply #1 on:** February 16, 2020, 06:18:14 PM »

That happens to me when I try to upload pictures that are too large.

ComfySofa · « **Reply #2 on:** February 22, 2020, 07:58:30 AM »

Engine strip underway...

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ComfySofa · « **Reply #3 on:** February 22, 2020, 02:20:27 PM »

More pics to come tomorrow - (just about to split the cases tomorrow) not sure if anyone can help but does anyone know where i can get this aftermarket cam chain tensioner??

Im all for improving any engine internals while its apart! (nip forward to about 3.50)

Rick4004 · « **Reply #4 on:** February 22, 2020, 06:10:20 PM »

www.ttr400.com

ComfySofa · « **Reply #5 on:** February 23, 2020, 01:16:53 AM »

Brilliant - thanks very much....cant seem to find the price or where i get them from anywhere (just emailed him) - wow - tons of other stuff isnt there..!

ComfySofa · « **Reply #6 on:** February 23, 2020, 06:13:06 AM »

Finally got there....

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ComfySofa · « **Reply #7 on:** February 23, 2020, 06:16:00 AM »

A question...as it came apart the bearing shells came out....does it matter which way they go back in....just a question...my mate is an experienced builder who will probably know....

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ComfySofa · « **Reply #8 on:** February 23, 2020, 06:18:24 AM »

Oh - more with the questions....ive obviously removed my cam chain tensioner....it was a tiny bit stiff on removal but once id cleaned with a bit of WD40 it was free...is it worth changing to the aftermarket version (mine having only done 6.2k)....or are there other reasons the aftermarket version is produced....

jakec · « **Reply #9 on:** February 23, 2020, 09:32:36 AM »

I did the same thing taking down my engine, lost track of the bearing shell placement. The short answer is yes. You need to find where they go. I did this through trial and error using plasti gauge.

ComfySofa · « **Reply #10 on:** February 23, 2020, 09:39:12 AM »

Would it be better to get new ones? or are they really expensive (i was assuming as the engine was split i was going to be replacing bearings 'n stuff wherever possible...)

jakec · « **Reply #11 on:** February 23, 2020, 09:40:50 AM »

You would still need to know what you had in the first place in order to know what to buy. I will try and find my thread where I went through this horror (I did live through it though).

Anyways, here is the parts list for my rebuild. You can use this to order the parts from a wholesaler like I did.

https://docs.google.com/spreadsheets/d/1gzKnJlJ90TDThwdJzzvti_F2JZVa16YmeUx4Bvt1FY0/edit?usp=sharing

jakec · « **Reply #12 on:** February 23, 2020, 09:44:11 AM »

Here is my thread. I haven't started reassembly yet. But you can see where I figure out the bearings on page 4. Page 1 is me going through the realization that I screwed up.

http://forums.sohc4.net/index.php/topic,179579.75.html

ComfySofa · « **Reply #13 on:** February 23, 2020, 09:46:16 AM »

Brilliant- thanks very much - i have a friend thats an engine builder so hes gonna be way more experienced than me....to keep his work to a minimum i said id strip it, get the cases done, do all the polishing then he said he'd come round and teach me how to re-assemble it...hopefully!

ComfySofa · « **Reply #14 on:** February 23, 2020, 12:36:08 PM »

Been through your thread. Your way ahead than me from a knowledge point of view....im still a bit lost as to what to order...mine has done really low miles 6.2k and that was very light usage....ie is oem stuff good for the engine or should i try to get OEM?

ComfySofa · « **Reply #15 on:** February 23, 2020, 01:20:21 PM »

Couldnt help myself - went back into the garage to double check and all the journals in the upper part of the crankcase are in place...i take it that would make matching them up easier?? (if that route of using the existing ones as the mileage is low (and very easy) this bike has never had a hard life...if anything the hardest life its had is sitting in storage in a damp shipping container...!

jakec · « **Reply #16 on:** February 24, 2020, 09:06:07 AM »

Keep track of where the bearings in the top half were, then use process of elimination to figure out where the bottom ones go.

As for the parts you'll need, I think you will need probably 90% of what I have in my list. I bought all the consumable parts like chains and stuff. Not much of the reusable stuff in my engine needed to be replaced.

ComfySofa · « **Reply #17 on:** March 28, 2020, 01:14:51 AM »

Been a bit quiet as my the bikes i use from day to day needed maintenance. Hypermotard sprag clutch went (thats now sorted). Also the rear swing arm on my z1000 needed to be recoated along with a load of other stuff, which is going back in today.

The frame and swing arm from the 400/4 are currently at the powder coaters - assuming he can keep working in the current climate (and that i can go and get it) should be ready next week.

Once my zed is back together - ill be able to clear the garage floor and go through all of the 400 4 stuff to get more powder coating together....pic will follow when i get the frame and swing arm back.

jakec · « **Reply #18 on:** March 28, 2020, 10:05:55 AM »

That’s how it goes, I also get distracted with other bikes that I ride needing maintenance. I’m going to start my rebuild today.

scunny · « **Reply #19 on:** March 28, 2020, 12:58:07 PM »

What model Hypermotard have you got, and thoughts on it.

ComfySofa · « **Reply #20 on:** April 02, 2020, 12:08:00 PM »

An old 1100 evo sp which is so far from standard its untrue...! Here you go...

ComfySofa · « **Reply #21 on:** April 02, 2020, 12:11:00 PM »

Its now that i find im getting old....not interested in the new ones that much...same for my rsv4 factory (pre aprc) no electronics. Just scored some Nix30 forks for it..winging their way over from the u.s.

The hyper is like a turbo charged tractor.!

ComfySofa · « **Reply #22 on:** April 02, 2020, 12:12:19 PM »

Frame and swing arm will be back from the coaters tomorrow. Its given me enough time to do a little bit of sorting out in the garage. Got the final pile ready tomorrow for the coater and a new pile for the chrome platers...

jakec · « **Reply #23 on:** April 02, 2020, 01:05:37 PM »

you'e going to chrome all of that? that's going to be really expensive.. where are you having it done?

ComfySofa · « **Reply #24 on:** April 02, 2020, 01:28:03 PM »

Probably not the pipe (that looks ok) but the rest yes (forks will get stripped on the weekend) - theyre getting done also, not sure what to do with the wheels yet - either rechrome - (but, a good clean might be all they need) but, all the spokes are rusted so no matter what theyre coming apart....or, stainless steel rims, or, brushed alloy...having said that im trying to keep the look....

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Author Topic: 400/4 Restoration (Read 3428 times)