Hi Cwac -

I still have my XR400R that I bought new in 2003, and after 48,000 miles on it, hopefully I can give you some pointers...

As you may (or may not) be aware, there are two version of the XR400 available in the UK - the 'Euro' version that came with a larger glass headlight with hi/low beam, speedo, and a combined AC/DC electrics (AC for the headlight, DC for the brake light and indicators) - although as other have pointed out, there was no battery on this bike, just a regulator/rectifier that provided DC once the engine was running.

The other kind was the 'Enduro' version (effectively the US model) that only had a smaller single beam headlight and a tail light - although this could be wired to provide a brake light too (using a hydraulic brake light switch on one or both of the master cylinders) as it has the same tail lamp unit & bulb... This bike was AC only, although again it was also easy enough to fit a regulator/rectifier and a capacitor to provide DC when the engine was running (to power a GPS etc. and smooth out the feed to the lights).

I bought the Enduro model, and did those mods - hydraulic switches for front and rear brakes, and a small reg/reg from Electrix with a capacitor to power my GPS, keeping things pretty much as simple as possible electrically, which is something I would recommend if you are prepping this bike for a trip...

As you've ascertained, the XR400 is about as strong and simple a bike as you can get, and I would recommend you try and keep it that way - especially electrically, since traditionally it is electrical add-ons that end up causing the most grief on a travel bike.

Personally I wouldn't bother with an HID conversion - it's unnecessarily complex and bulky, and I don't imagine you'll be doing all that much night riding anyway (after all, it's not really recommended, especially in countries where animals roam free). Instead I would fit a pair of LED lights - for example, the Vision-X Solstice lamps I have on my bike now only draw 10w each, and provide 900 lumens each, with a flood (for low) and spot (for high) beam.



Being just 2" square, they also fit inside the OEM headlight mask (the smaller Enduro version) really neatly, and I used the original plastic lens as a stone guard.

Using a pair of these (or similar) immediately saves you 15w of stator power over the standard 35w headlight, even on full beam - and if you also replace the brake/tail-light bulb with a LED version you'll save even more, which means that you won't even need to change/rewind the stator if all you need to run is a GPS and a 5w charging socket for a phone etc.

If you do want a bit of battery power (to keep the lights on, or the phone charging when the engine isn't running) then I can recommend the small battery that Baja Designs make:



It's as if it was made specifically for the recess in the top of the XR400 air-box!

I've fitted this battery as part of my most recent modifications, so I can still run my rally navigation gear without the engine on.

You basically wire it in instead of the capacitor, but be aware you'll need to include an in-line diode to stop any back-flow (discharging) back into the stator, and of course a switch between the battery and the rest of the wiring loom to turn the lights etc. on and off.

This is all straight forward to do, with the minimum additional wiring, which I'd suggest is the key to reducing potential issues once on your trip.

As for oil changes - I typically change mine around 1500 miles (2500kms) at trail-riding pace, and change the filters each time. The Hi-flo ones are fine.

As others have suggested, keep a daily eye on your oil level - especially if you've bee running at high speeds for long periods. My bike did eventually start to use oil after about 35,000 miles... and I had the engine rebuilt earlier this year with a new piston and rings, and the valves reseated and new seals, and it's like new again.

The XR is a keeper ;o)

Hope that helps...

Jenny xx