BUILDING AN XR400 ENGINE WITH ELECTRIC START!

Jeff Castine shows us how to rebuild an XR400 engine (cases split) and put back together with components allowing for use of an electric start!
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[@Batteries456]

You’re the man, Jeff! Hope you’re fully recovered and ripping wheelies soon back here in New England!

[@GQ-wz5it]

A video series of you traveling around and helping folks out with their projects is something I would look forward to watching. I hope you heal up and feel better.

[@shawnslaunwhite2085]

Traveling and helping others with bike projects sounds awesome! Great for the project owners and the viewers. Be well and great video.

[@corylangille1869]

I did this mod on my 2000 XR400r and I love it! I did the 89mm cylinder with HD head studs and stage 2 hotcam also.

[@twomuchskll]

We support Jeff !!!! Glad you are ok !!

[@kyleharkness8179]

One of the best videos I’ve ever watched. Keep making them.

[@philthome1303]

Good to see you back in action. That was quite a fall. Keep on keeping on Jeff 👍🏍🏁 Missed you at BikeWeek. Met and rode with your son, though. Good guy 👍

[@jeffcastine2244]

This is Jeff Sun Jr thanks Phil that was awesome for taking us out of the Town had a good time meeting you as well

[@kennyrichard2971]

😱 Jeff that was absolutely crazy I am so glad you’re doing better now I enjoyed your video

[@davidcisco4036]

1:52 Here in USA the XR400 were sold from 1996 - 2004. In Japan a XR400 Motard were sold from 2005 - 2008.

[@daffyduck9901]

Chief that was a big hit. I'm glad you're okay or made it out anyways and look at you right back to it. Amazing can't hold a good man down. I miss seeing and hearing your expertise you have a lot of knowledge. Wish you the best bro🤙

[@fitzstermoto]

Jeff, that fall looked excruciating and I'm so glad to see you're moving around and starting to feel better! Most of all I'm glad to see that you're okay, although it was bad enough, I suppose it could've been much worse. Thanks so much for sharing that was a really cool project and may God Bless you and continue to heal you! Thanks for all you do at Kaplan Cycles and NEMM!

[@RealInventions1]

yeah it sure looked scary to fall like that ouch ouch get well asap

[@Drivehead103]

You've done it again! A video with one of my childhood dirt bikes. Honda Z50 a under the gooseneck of the trailer at the beginning of the video. Identical to the one I had, the first motorcycle I ever owned. So that wraps it up, Honda Z50A hardtail, Honda CT70 trail bike, 1974 Honda xr75, 1976 Honda CR125 and 1986 Honda CR250. Amazing how you have had them back-to-back almost in the same order I got them! Only motorcycle you have not shown that I have owned is a Honda xr250r prolink. Seems like it was a 1984 model, maybe 85 or 86. I love this channel!

[@daves984]

Lucky guy to have a master mechanic staying with him.

[@morganeast3403]

You r so cool to do that it fkn 🔥, as a retired machinist I always work on the kids bikes a lot,free,they get the parts ,average flat tire week is 4 every week I have gotten very good at it lol,good job great vid ,your a wonderful man,sorry about the accident.

[@JonIronhorse]

What a bad ass! Praying you get back in wheelie shape in record time man. Thanks for getting us caught up.

[@ashtonmariefranklin725]

I've built a few EX400 engines, basically a xr400. In an ATV. I turned 1 into a stage 3 440 with cnc head porting, and ran had an edelbrock carb, white brothers rev box, kibble white valves. Hinson race clutch setup, And my second one was basically the same but stroked out to 465cc. Which was a handful to ride it would wheelie easily in every gear.

[@williamrizzo1285]

I'm glad to see that you are back wrenching Jeff, never give up!!!

[@mikebowers518]

Omg Jeff! I'm Glad You are up and getting around. I Hope for you a speedy and healthy recovery.

[@Theairguitarguy]

Epic, I want to get an xr400 and put a starter in it!

[@Nick-qv5jq]

Love the t-shirt Manic - 'I see stupid people' - classic! Hope you have a speedy recovery

[@cwalton56]

What a great add-on. Turns a great bike even better.

[@jerrymarcum9981]

So tragic ! Hope your recovery goes well. He makes the assembly look so easy. Skills.

[@LSCBTHEWAVY]

The manic mechanic is a cool ass name 💯😂 shows u have a good humor

[@2-strokeracer531]

Ol' Jeff growin' that hair out... 🏁🇺🇸🏁

[@bobg1219]

That was a nasty fall. It could have ended worse then it did, you're a tough dude Jeff. Thank you for the engine assembly video 👍

[@stevenbrooks1243]

Sorry about your fall I hope you heal up with no issues

[@shoominati23]

Hey I found the best thing to get cases together is the heat the bearings with a heatgun and get that air duster compressed air in a can stuff and turn it upside down and spray the end of the whatever shaft you are trying to make fit as it's basically like liquid nitrogen when you spray it upside down (dont get it on your skin) and it gives you much more leeway than heating in the oven or freezer as if you mess up the first time with those methods you dont usually get a second try.

[@joshc6591]

I love seeing the xr400r videos. They are awesome bikes and the here isn’t enough content about them out there

[@scottyd2262]

Who else let out a big cuss word when Jeff hit the ground ? Glad that your still with us Jeff, that looked really bad..

[@leevail3729]

Nice to see Jeff back on the channel. Speedy recovery man. LnR.

[@empiresrikesfat]

Damn that was a big fall, glade to see you back on the tools, hope for full recovery!

[@chrisrieger3311]

A master at work!!

[@jasonrutherford1722]

damn im glad your ok brother my dad took a fall of a roof not as high up as yours but damn shit happens fast im glad your still with us god bless you brother !

[@bobbymckinney1264]

This man knows his stuff very good guy,this motor will run like a top

[@ibelieve96]

Atleast you got it on video! Heal up buddy!

[@MegaSkypes]

You make it look so easy! Great project better than limb lopping!

[@royculleton6223]

Jeff.. We are old dudes man! We can't fly!! Glad you are on the mend!! Next project add a kicker to an older DR350/400 that is e start only! I might know where one is located!!!

[@BraapEffex]

They are the same basic motor but there are differences such as the center cases for the electric start and also the tranny gears are different on the four wheeler. Stronger more robust to handle the extra strain and weight of 400ex. Use to do Frankenstein swaps back in the day! 👍

[@svenomick5857]

Jeff You are lucky to be alive, great work enjoy Your time off Mick Australia.

[@keithfenwick5502]

Excellent stuff, great format for a future YT show, get well soon god bless America 🏴󠁧󠁢󠁥󠁮󠁧󠁿🍀👍🙏

[@tannerbushey9196]

Would love more of manic mechanic videos 👍

[@MusicSensations1971]

Pretty cool project there manic mechanic get better heal fast godspeed and God bless America

[@80MusicVideos1]

Leave the tree stuff to the pros.. Those ladders will kill ya! Glad your back to spinning wrench’s again👍🏻

[@pirocaoPOWER]

Good morning, here in Brazil honda launched a motorcycle with the XR400 engine with electric start, its name is NX4 Falcon. It was released in 2001 and stopped production in 2015. Engine identical to the XR400 but with less power.

[@OldDirtBikes]

Been wondering when we would see you again , man that fall was bad i felt the pain just watching hope you best wishes and get well soon. I could watch you all day putting bike engines together and commentery was very helpful . You make it look as easy as preparing tost and jam . Your idea of going round the country fixing peoples projects is awesome i will watch everyone 😀👍👍. If only you would come to uk 🇬🇧 to teach me on my honda xr’s collection. You can see my collection on my KZbin channel 😀. Great vid looking forward to the next one 👍👍

[@simonsled661]

Put that beast in the frame and hit the magic button please!!!

[@mitchellbushee1991]

Hey Jeff. Ty here. Hope your healing up. Nice video. 🇺🇸

[@ronniewilliz153]

Naples lol that's my hometown that's where I was born an raised an grew up. Holy crap that's a huge fall. Glad ur ok.

[@enr74]

HAVE A QUICK RECOVERY JEFF.WITH THAT NEW PLAN FOR THE WINTER YOU SHOULD HAVE A PROPER DEDICATED CHANNEL ,I'VE SEEN ALL YOUR VIDEOS AND ALWAYS FOLLOW YOUR ADVICES. HAVE A GOOD ONE

[@motolitho1]

Wow, what a cool dude. And a great idea.

[@seanbucktrout593]

Dam Jeff, that's abit of a fall you had there get well soon buddy thinking of ya👍🇦🇺

[@LifeWideOpen780]

Jeff is awesome

[@owensbama1923]

That's cool. Hope you make alot more videos brother.

[@markdixon4912]

I will definitely call senior, I have a 2009 xr650l I would like to modify with the piston cam and port work

[@1991enduro]

iive heard a trx 250 works for the xr250r id love to do that or can any one point me in right direction il say it again if the xrs had e start they would still be produced today and no im not on about the 650l lol this the best channel on youtube this mechanic is the on the wizard keep him on the videos to hes a real of knowledge

[@georgekefallinos8120]

Be well fast Jeff :) be careful

[@noremaccystoms2195]

Cool idea

[@michaelrudisill897]

Can you show us how you mounted the battery and rectifier?

[@danielosmon]

Nicely done

[@carlatamanczyk3891]

I have a 2003 XR 250 with a 280 kit. Bike is still like new but I wished it had Estart.

[@tommybritton9273]

Awesome video jeff

[@jeffwilkins3052]

Goodness, I crenged at Jeff's fall. 😖 Another GREAT BUILD though. 😎

[@seather863]

Glad to see Jeff is doing well, looks a little sore still. Manic will be wheelieing a bike soon enough... Can't keep a good man down.

[@todd8109]

Jeff glad you are doing better. That’s one hell of a fall

[@andym1535]

Nice video

[@MitzvosGolem1]

Good idea shop repair mechanic vids .

[@connormacquarrie1831]

Great tips!!!!

[@carrielula5103]

Hey Jeff, thanks for the video and glad you're making a swift recovery - that was quite the fall. Can I use the flywheel from the xr400 and add the starter clutch from the trx400 to the back? Or, must you get the flywheel from the trx400 as well. Thanks!

[@deejc021]

This is awesome! I have almost acquired all the parts for this myself. I'm curious if you recommend the xr400r wiring harness or a different one? I found elsewhere online they recommend the CDI Box for the 650R. Would a wiring harness for a 650R be compatible? They look almost the same. Also curious what specific flywheel you show here in the video? Is that not the stock one?

[@shawncordeiroTerraceBC]

NICE WORK so they say the xr has at least 4hp more then the ex does Anyone know what the differances are between ex vs xr, to make a 4-6 hp gain ?

[@RUSTY-A-L]

There is a Honda street bike sold in Latin America that uses an electric starter & some with fuel injection called the NX Falcon 400. I don't know if the conversion would be the same or just a bolt on.

[@Mr58hawkeye]

Do you put any oil of any kind on the cylinder bore or rings? or put it together dry? do you have to lap the new valves into the old seats?

[@jeffcastine2494]

Hey Jerrry/ yes piston and rings go together dry and dry cylinder.I would of reground the seats if I had my valve tools with me

[@pcduc64]

Where did you mount the starter relay and rectifier

[@cyclerider5652]

You heal quick. Good to see you are back on your feet. I just went from an old XR kick start to a new elect. start bike. I was against elect start at first, but it is nice because my old XR sometimes required many kicks when cold or if flooded although it always starts. Do you know a good way to clean years of baked on mud from those XR cylinder fins? Thanks

[@Eric-fq5wx]

I've got a 64 honda superhawk 305 that I am going to restore if you want to travel to CALIFORNIA next winter

[@cliff1551]

Got a big tree wants trimming Jeff 🤣

[@bananabrooks3836]

That tree work accident couldve been much worse. As Harry said, "A mans gotta know his limitations".

[@ericdebisz9458]

Jeff holy crap you fell out of the sky!! No more ladders. Good to see you though

[@jonty4664]

Proper dude 👍🏻👊🏻✊🏻

[@fs4h]

That shirt is mint! Haha

[@minibikemadman]

Sweeet!!!!! Hey kaplan do you guys have any supermotos in stock ?

[@KaplanCycles]

Cr500 supermoto www.kaplancycles.com

[@joshuarobbins9264]

Can you send me the link to the 400 engine install?

[@shawnslaunwhite2085]

Oh man, I hope you recover quick, scary buddy.

[@jacoblatour6192]

why the crank as well?

[@noidontthinksolol]

its like a baby xr600

[@brunosousa1977]

Now for the 650r

[@milesman69]

No man with valuable skills such as yours should be allowed anywhere near a ladder or a tree

[@DanNZ69]

Does anyone know the difference between the Trx400ex motor and the Xr400? Apart from the gearbox and e start?

[@johnnygeorgopoulos4072]

You're a nut Manic, but I guess that's where you get the nickname 😅 That was a nice fall you took, reminded me of about 20yrs ago I was street riding my 84 CR250R back from getting gas and cigarettes and as I was heading down the main road, a very older lady (at least 80yrs old) was up on an A-Frame ladder sideways on her hilled front lawn trying to trim the top of an 8ft tall evergreen.... she heard me coming down the road, looked in my direction, and her at the very top and the ladder came falling down.... I flew over, literally dumped my bike on her lawn trying to rush to her (I purposely laid it down) and as I was running to her, she literally POPPED up like a damn spring and screamed "I'm ok!" 😵‍💫😅 I scolded her for being up there, asked where her children or grandchildren were and why they weren't doing that instead of her, she said "oh those boys are lazy and I decided to do it myself" 🙄 So I told her, if she was really ok, to go relax, I put up the ladder correctly this time, finished trimming that and the opposing tree, cleaned up everything, and was rewarded with a tall fresh glass of home squeezed lemonade and a her trying to give me money, I took that lemonade of course and told her to come get me if her lazy children refused to help her. Edit: dude, glad you're ok, and would absolutely love if you ended up traveling around and documenting working on other people's side project bikes....too bad I got rid of my last 3 bikes due to a neck injury and thinking I couldn't ride anymore (SOHC CB750F, DOHC CB750F, and a FCR carbed CBR1100XX), I'd have gladly taken you up on just some preventative maintenance and given you my Astro CS AWD 😅

[@Вячеслав-о7в1ч]

Корисне відео.

[@sonnyseabury4051]

Damn Jeff, that was a bad fall. Sorry that you had to go through that. I pray you made out well. I'm petrified of heights, and tall ladders. That would have scared the shit out of me. I'd rather ride a CR 500 blindfolded, before climbing way up there.

[@MrHondatrxex]

Just use a 400ex motor, put a xr400 cam in it. Alot easier and practically the same thing with less hassle

[@rhiekel]

I have a beautiful xr400 kick start. I have had my right knee replaced so makes it hard to kick start. I would love to make it electric start. So come on out to southern Oregon and help me convert it !! I have a workshop, as well as a beautiful wooded property next door with water and power you are welcome to stay at. :-)

[@the_katman2181]

Man, that was a horrible fall. Glad you're okay.

[@marksullivan9575]

Learn from our mistakes,

[@youtubedannywayne]

500 DIRT BIKE LANDING 123 GO SIGNATURE KAPTIN

[@youtubedannywayne]

COME ON MAN ITS A TWITCH OF THE FINGER

[@youtubedannywayne]

ATT KAPLIN AMERICQA

[@francoismoreira1583]

👌💪🏻🙏

[@danielarney9729]

Man, you work with this guy for a day your going to learn some shit no matter what your experience. Like don't climb ladders if you drink beers for breakfast, (ryobi makes a nice pole saw, and might be able to use roof of camper) just kidding, but he should be teaching motorcycle class in a highscool/trade school with the summers off.