'99 XR400 gets UPGRADED USD forks

This video covers a fork/shock USD (upside down) upgrade for a 99 XR400.
I took the front suspension assembly from a 2006 Honda CRF250 and installed it on the XR400 using a conversion steering stem from XR's Only and a Pivot Works bearing kit.
Part Numbers:
Steering Stem:
- XRSS-CONV
Steering Stem Nuts:
- HO53229-MN1-670
- HO90304-KA3-710
Pivot Works Bearing Set:
- PWSSK-H04-420
Also bought this stuff for a 2006 CRF250 off ebay:
- set of front forks
- full triple tree/headset unit
- front wheel/tire combo
There are a few ways to do this conversion.
* You can buy the steering stem from XR's only that fits the CRF triple tree and allows you to use stock XR headset bearings. (easiest route)
* You can buy some custom bearings that will fit the stock CRF250 steering stem and the races will fit the XR. (the bearings are smaller though and require spacers otherwise the stem will be loose top to bottom)
* You can machine the CRF stem to a smaller diameter so that the stock XR bearings will fit the CRF stem. (cheapest if you have access to a lathe and the knowledge to use it)

[@flapwheat]

This is the best video I've found regarding Honda XR USD/inverted fork conversion. Thank you! I had to resort to internet forums when I wanted to swap my old XR250 and ended up buying old CR500 triples and cobbling together parts to make it work. Good job!

[@MakeFixUpgrade]

Thanks! Glad you liked it! I had to hunt for info as well so figured I’d make a video for it.

[@TerrenceLP]

Based on what I found, 2005 - 2007 Suzuki rmz triple tree fits, stem height etc. The conversation bearings ar 30x47x12 and I used a thrust washer spacer for a perfect fit. Now any 47mm fork should fit 💪👉👍🤞

[@Crxpert1]

Very helpful. Thank you! I Love that you included part numbers.

[@MakeFixUpgrade]

Thanks! Glad you like it!

[@jamespolucha8790]

Nice job

[@dwaynebottcher8714]

Thanks for the video I'm in the process of doing this swap myself

[@MakeFixUpgrade]

If you have any questions let me know!

[@tomcooley6019]

@@MakeFixUpgrade any chance you could provide links to the exact parts you ended up using?

[@MakeFixUpgrade]

@@tomcooley6019 the part numbers are in the description. I’ll see if I can track down the links tomorrow.

[@munoz20]

nice video man

[@munoz20]

post riding videos would love to see a walk around and ride of your 400

[@MakeFixUpgrade]

Thanks! 🙏

[@Mitch-bf2dm]

Bought a 99 brand new..put an aloop kit and whitebros pipe. Wish i still had it

[@MakeFixUpgrade]

They’re a great bike!

[@luisbatista597]

💪💯😎

[@kyleclosen622]

Wondering how the headlight mounted up the CRF triple clamps? Or does it just mount onto the tabs onto the side of the clamps?

[@MakeFixUpgrade]

Headlight mounted fine. No modifications needed. The rubber clamps fit perfectly.

[@tben9357]

Thank you so much for the vid! Do you know if this same setup will work on a 96 xr400 also?

[@MakeFixUpgrade]

It should work on any xr400. I believe they’re all the same for the most part.

[@1176hambone]

How was the balance between shock and forks? What are your clicker settings on the suspension? Cheers!

[@MakeFixUpgrade]

The balance felt good to me. I don’t recall the clicker settings. This was a project bike that I bought to rebuild. I have since sold it.

[@pcduc64]

What is the part number for the thinner bearings to use the crf stem..? Thx

[@MakeFixUpgrade]

I bought the thinner bearings from TWF Racing. I emailed Zoran at twfracing.com and told him I was looking for bearings with the measurement 30mm ID X 47mm OD X 14mm thick. He gave instructions for how to pay and shipped them to me. I actually still have several sets and some spacer washers as well. You can dm me on IG @make.fix.upgrade if you're interested in them.

[@jamesbramblett3346]

How much longer are the CRF 47 mm forks than the stock XR 400 forks? And how do you compensate for this? Can you just run the forks higher in the clamps enough?

[@MakeFixUpgrade]

I believe the CRF shocks are about an inch longer. You can run them a little higher in the clamps if you want to. I'm not but there's some room.

[@pcduc64]

so. . i guess my question should be is, the pivot works pwssk ho4 420 the smaller bearings for the cry stem and the xr race?

[@MakeFixUpgrade]

The pivot works pwssk ho4 420 bearing set is used if you buy the replacement stem from XRs Only website.

[@pcduc64]

I need the part number for using the crf steering stem on the xr400

[@MakeFixUpgrade]

I replied to your other comment with details of where I got the bearings.

[@nonoantonio98]

very nice. how much clearance do you have between the forks and tank?

[@MakeFixUpgrade]

It just touches the tank. I’ve seen some where you drill the lower clamp and install stops but I didn’t do it.

[@paulh.5691]

Why not apply some heat to "the triple tree" to put the new stem in?

[@MakeFixUpgrade]

It’s a pretty snug fit. You might be able to heat it and beat it but the press works great.

[@GahBoe]

What sort of terrain did you ride with the XR400? Think it was worth upgrading to the larger USD forks for trail riding?

[@MakeFixUpgrade]

Mostly local trails and fire roads. I personally like the USD shocks better but I wasn’t unhappy with the XR forks. I felt the USD upgrade provided better handling. I’m not always trying to ride at full capacity though. If you have the cash to do it it’s a fun upgrade.

[@Fieldyfan94]

So if I buy the xrs only rod piece I can just put a crf front end in my 85 600r no machining anything?

[@MakeFixUpgrade]

I’m not sure for an 85 600. I would check with XRs only to confirm the year range

[@Fieldyfan94]

@@MakeFixUpgrade I tried but there customer service is horrible never even replied

[@josetomas1111]

Do u know if I can do de same but with a crf 450 as a donor for a xr400r?

[@MakeFixUpgrade]

I believe so. As long as you can source some bearings it should work.

[@josetomas1111]

@@MakeFixUpgrade thanks

[@kyleclosen622]

Also will the XR wheel bolt right up or do you have to get CRF wheel and hub?

[@MakeFixUpgrade]

I didn’t try to mount the XR wheel. I just bought a used CRF wheel and hub assembly.

[@1176hambone]

Spacers can be used for XR wheels. Emig racing is a good resource on these USD conversions

[@1176hambone]

Steering stops?

[@MakeFixUpgrade]

I didn't end up putting any on.

[@hadrienaubert7]

Hi, are you still happy with your fork swap ? I was thinking about replacing spring by stiffer racetech in addition to racetech gold valves, especially in order to keep original fork and look.... but I'm still in reflection time ^^. Thanks for your feedback.

[@MakeFixUpgrade]

I liked it while I had it but have since sold the XR and switched bikes.

[@unclequack5445]

You got a lot of $ in that bike.

[@MakeFixUpgrade]

Haha yes I do!

[@brettfine9674]

Y

[@MakeFixUpgrade]

Because I can.

[@jeffsilver4730]

nice installation! 1 to 10...... how much better is the ride now?

[@MakeFixUpgrade]

@Jeff Silver thanks and I’d say a 10. Definitely worth it. More stable, more suspension travel, doesn’t dive like the stock forks do.