Cost to Rebuild

I just got done rebuilding my 99 400 which I upped the displacement to 426 with the OEM cylinder and piston. Thought this might help those who are contemplating a rebuild. Pretty inclusive of all the parts you'll need. I pretty much stuck with OEM parts which I bought from a dealer at ~ 20% discount. I could have saved some $$$ by buying from the TT OEM store but I was kind of helping the friend of a friend. I suspect the prices are pretty comparable for anyone rebuilding a newer model (450).

CRANK ASSY.* 5JG-11400-10-00 $366.08 1 $366.08

Bearing (Crank) 93306-30633-00 $34.10 2 $68.20

Piston NG-11631-10-00 $146.03 1 $146.03

Piston rings 5JG-11603-00-00 $28.95 1 $28.95

Piston Pin 5JG-11633-00-00 $12.19 1 $12.19

Circlip 93420-19084-00 $0.17 2 $0.34

Cylinder 5JG-11311-00-00 $260.30 1 $260.30

Cylinder Gasket 5BE-11351-00-00 $5.33 1 $5.33

Cylinder Gasket (H)5JG-11181-00-00 $35.55 1 $35.55

Cylinder Head 5BE-11102-10-00 $569.93 1 $569.93

Head Cover Gasket 5BE--11193-10-00 $24.47 1 $24.47

Intake Valve 5BE-12111-10-00 $10.01 1 $10.01

Intake Valve 2 5BE-12112-10-00 $9.90 2 $19.80

Exhaust Valve 5BE-12121-10-00 $24.20 2 $48.40

Seat Valve Spring 3GM-12126-00-00 $2.82 5 $14.10

Spring Valve inner 5BE-12113-00-00 $3.66 3 $10.98

Sping Valve outer 5GR-12114-00-00 $4.57 2 $9.14

Rtnr Valve Spring 5BE-12117-00-00 $3.11 3 $9.33

Rtnr Valve Spring 4GY-12117-00-00 $2.94 2 $5.88

Valve Cotter 1AA-12118-00-00 $1.18 4 $4.72

Valve Cotter 1WG-12118-00-00 $1.10 6 $6.60

Seal, Valve Stem 33M-12119-00-00 $5.71 2 $11.42

Seal, Valve Stem 4SV-12119-00-00 $2.37 3 $7.11

Hot Cams (In) HC_4002-1IN $152.96 1 $152.96

Hot Cams (Ex) HC_4001-1E $80.96 1 $80.96

Gasket 5JG-15453-00-00 $5.54 1 $5.54

Oil Seal 93102-32480-00 $6.92 1 $6.92

Primary Gear Drive 5JG-16111-00-00 $34.96 1 $34.96

Nut 90179-20001-00 $6.53 1 $6.53

Lock Washer 90215-21001-00 $2.74 1 $2.74

Crankcase Gasket 5BE-15462-00-00 $10.98 1 $10.98

Crankcase Gasket 5BE-15451-00-00 $4.05 1 $4.05

water pump shaft 5Gr-12458-00-00 $23.93 1 $23.93

wtr pump oil seal 93109-11073-00 $3.00 1 $3.00

wtr pump oil seal 93102-12321-00 $4.47 1 $4.47

Cam Chain 94591-50120-00 $28.05 1 $28.05

Cam Chn tensioner 5BE-12210-00-00 $49.63 1 $49.63

Tensioner Gasket 4FM-12213-00-00 $1.05 1 $1.05

Total: $2,090.63

thanx for the list.

i hope i wont need all that when i do mine.

Thanks! I also have a 99 WR400. So far it is still running OK. I did notice some smoke at start up the other day (when revving the throttle). Only when I let it run a long time with the cold start knob out however. The smoke appeared to be white, not black as you might suspect due to excessive fuel. After the engine is warm, it no longer smokes. I am thinking valve seals?

What was it that caused you to rebuild your engine? Were you getting "noises"?

Bob

What was it that caused you to rebuild your engine? Were you getting "noises"?

Bob

One of my intake valves broke, wiped out both the head and the piston. I had about 9000 miles on the bike when it happened. Hindsights always 20/20, I would strongly encourage a fresh top end after 7500 miles or so. Paying for new valves is a lot less expensive then everything I did. I would also add that I was pretty meticulous with the maintenance, oil change every 500 miles, clean air filter every other ride.

What was it that caused you to rebuild your engine? Were you getting "noises"?

Bob

One of my intake valves broke, wiped out both the head and the piston. I had about 9000 miles on the bike when it happened. Hindsights always 20/20, I would strongly encourage a fresh top end after 7500 miles or so. Paying for new valves is a lot less expensive then everything I did. I would also add that I was pretty meticulous with the maintenance, oil change every 500 miles, clean air filter every other ride.

Oooh! You do your oil changes every 500 miles? Maybe you meant 50 miles. Perhaps I am mistaken but I thought these bikes required more frequent oil changes. I do my oil changes every 60 to 70 miles. If a real long ride sometimes it will stretch to 100 miles.

Am I doing my oil changes too frequently?

Bob

every 50 miles !! Ya that might be getting alittle carried away :thumbsup:

I would think 3 - 5 hundred is just about right :thumbsup:

I change my oil a lot also about every 150 -200 miles or every three to four rides I change my oil and clean the filter but I also want the best clean oil in my bike hopefully it will make a difference later.

Cool! Thanks for the responses! I will change my oil change frequency. At least I never had to worry about oil breaking down! :thumbsup:

Bob

500km tops on the oil!

rockieman

thanks for comprehensive list of parts and costs. i, too, hope i wont need all of those.

just a few questions

how does it go now?

how much do you notice an extra 24cc.(as you are possibly still in run-in stage i'll wait for that answer)

is yours YZ timed?

your friend of a friend should be fairly grateful.

good luck

Just paid about that much for a engine failure caused from the Hot start piston in the carburettor being seized open. Causing a inlet valve failure.

The lean mixture over a long period is not good but on the bright side I got a cheap bike off my brother

rockieman

thanks for comprehensive list of parts and costs. i, too, hope i wont need all of those.

just a few questions

how does it go now?

how much do you notice an extra 24cc.(as you are possibly still in run-in stage i'll wait for that answer)

is yours YZ timed?

your friend of a friend should be fairly grateful.

good luck

I have a slight coolant leak coming from the metal pipe into the head, hope to fix tonight and begin the break in process. As far as the YZ timing, I actually changed back to the WR based on the majority of the riding I do (tight trails) the WR timing suits me best.

:thumbsup:

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