XR400 frame building
 

Im doing a trip to west africa and am using the xr 400
i know the subframe is lightly built and wouldnt mind doing some welding to make it stronger , has any body made these modifications on a 400 ? if you have i would appreciate any advice on where you did the welding to make the sub frame stronger , what metal you used etc.
if any body else has done a trip on this bike i would also like any handy tips you have for this machine,cheers

This is true, the subframe on the XR400, especially the '96, is marginal even if unloaded. The subframe on my '96 cracked after less than 200 hours use (never any luggage), and even though I bought the Honda extended warrantee when I bought the bike new, Honda refused to cover it under warrantee. Then they updated the subframe on later years because quite a few people were cracking them.

BBR makes an aluminum subframe for the XR400. From my experience, it is not necessarily stronger than the stock subframe. But you might give them a call. If you have a special application they might be able to weld up something special for you with extra reinforcements.

http://www.bbrmotorsports.com

thanks mike ill check out cheers bruce