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  #1  
Old 16 May 2009
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Increasing the oil capacity on a dry sump bike

I have an XR400R, and it has a pitifully frequent oil change schedule. This is no surprise as it only carries about 2 and a bit litres of oil and is air cooled, so the oil works hard, plus the filter is teeny.

Does anyone know of a system/theory for how the oil capacity could be increased?

I had heard a suggestion once of putting another oil reservoir along the oil pipe route between the frame reservoir and the engine, but how workable might this be?
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Old 17 May 2009
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Oil.

Hi.
How abourt increasing the tank (frame) volume at the point above the motor behind the steering tube by welding a chamber to the main oil reservoir?
You could cut a few slots into the oil tank and weld on some plating to the cross brace above the motor. You might get another litre or so.
You may need to re-locate a couple of items but it may be do-able?
Does your XR have an oil cooler?
Maybe the MILITEC product may interest you?
Good luck anyway, I'd be interested to hear how you get on.
Dave.
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Old 17 May 2009
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Consider fitting an oil cooler-
I did (on my already water cooled F650) - when the going gets hot- one can never have enough cooling! it does save beating the heck out of your oil.
Depending on the outside temperature and whether I am working the bike hard, I have set mine up so as the new system can either be 'switched on' or left 'off' as in normal sump-to-header-tank. Keep an eye on the oil temperature gauge. It is important as over-cooling is not a good thing either- the oil needs get up to normal running temperature.

It may well worth a little time in the specialised forums for info about your bike.
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Old 17 May 2009
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There already is an oil cooler on the bike. Its semi-circular and resides under the headlight assembly.

I think it is standard, but no way to tell.

As for increasing capacity, I had though a secondary reservoir between the motorsump and the frame reservoir.

However, going on with the frame weldding idea, welding a section along the front face of the frame (ie directly behind the front wheel), provided the front wheel does no catch itunder fork compression could add a goo litre without having to butcher the tank and loose fuel capacity...
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Old 17 May 2009
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Yeah, could work.
A square secton tube could give you a few more cc's.
Been a while since I had an XR400 but the 600 has a lovely space between the main cross tube (oil res) and the brace above the motor, you'd get away without modding the fuel tank at all.
The gap by the upper oil pipe union could be plated off, the union re positioned and the pipes altered, If this is similar to your XR400 frame that is.
The only thing I can think of that you might have to watch is when the motor is off, the oil drains to the motors sump and gets pumped up into the frame when it starts. A larger amount of oil sitting in the sump (an extra litre or so) when the bike has stood may cause a hydraulic lock with the downstroke of the piston on initial start up! I can't see it being a prob but just a thought! Depends how much volume is in the crankcase.
As mentioned, I'm interested in how you get on with this, all the best bud.
Dave.
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Old 17 May 2009
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Try and search around, I've seen an engineguard with a built in oiltank. Maybe some of the guys using a XR 400 for Paris-Dakar have done something like that.
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Old 21 May 2009
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Quote:
Originally Posted by Warthog View Post
There already is an oil cooler on the bike. Its semi-circular and resides under the headlight assembly.

I think it is standard, but no way to tell.

As for increasing capacity, I had though a secondary reservoir between the motorsump and the frame reservoir.

However, going on with the frame weldding idea, welding a section along the front face of the frame (ie directly behind the front wheel), provided the front wheel does no catch it under fork compression could add a goo litre without having to butcher the tank and loose fuel capacity...
that oil cooler is standard.
i've been thinking about the frame welding option a long time. when it is time to rebuild the engine.. the frame will be altered as well
btw i got a nx not a xr but it works the same
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Old 21 May 2009
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Don't weld on the frame. You might weaken it and nobody will buy a bike with welding on the frame.
You have to build a tank anyway, so why not make it for bolting on the frame or as suggested make an engine protector with a built in tank. Both could be unboltet before a sale.




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Last edited by pbekkerh; 21 May 2009 at 18:15.
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