Circlip kits?

[Liamthedevastator]

Hiya folks,

I've got my engine stripped to almost just the casing but I'm starting to look for rebuild parts now. One of the big things I read is that one should never reuse old circlips.... well if i've taken almost all of them off then that is a lot of circlips to buy!

Money is not the problem, but getting the correct number of parts in the right sizes is. Does anyone know of a complete circlip kit for the '77 xs400? Or perhaps a list? If not then I will compile a list of every damn circlip in this puppy and post that shit to the internet so that nobody has to suffer this ridiculousness again!

Thanks a bunchion

 

[AMR-XS400]

mate same vote here, someone please help

 

[drewpy]

the only circlips i bought new was the piston ones.

so long as they are still springy, they will sit in/on their groove.

I bought a box of varous circlips from Aldi for £2 and dip into them if need be.

 

[xschris]

Always use new clips! They are cheap and any yamaha dealer should have them I think I paid like $8 for all four of them.

 

[arfstrom]

Okay, this is my list that I created for my "81 XS400SH" for a "Bottom End Rebuild" I created the list looking at everything that said Clip etc... Then when I got into the tear down, I quickly determine that If I don't need to rip it apart, I am not going to order extra parts. I did order a complete gasket set from Ebay, which includes everything for a Top End rebuild, (filing away till next winter, or the next one) I used the gaskets that I needed from that. Also orded a OD oil seal from Ebay, that was for an older bike, but fit fine on my Clutchrod OD seal. I know I am going to replace my Clutch plates, Springs, and Kickstart OD Seal when I do that. I also found that when dealing with my local Bike shop on the phone, I can walk them right to the part I was pricing/ordering. with my parts manual. I am sure I got this from here, but if not, I will add to this post. (just in case) Since there was nothing obviously wrong with my transmission, I only needed the replacement plugs, and 2 to 4 circlips that are hidden by the plugs. and the shift cam big circlip. I was able to order parts from boats.net, and http://www.powersportsplus.com/ Parts seem to be less expensive at powersportsplus. Any part that i was able to get immediately locally, I jumped at it. Shipping in the US wasnt that bad, maybe, for $10.00 5 circlips, Boats charged me $6.95. Where the local, might have been equal at the end of it all. don't forget checkout Ebay, Amazon.

Reason I did the bottom end was to replace the bottom crankcase so that the kickstart journal was good, and the kickstart would work. I was successful.

Code for most of the list (Example Clutch)
Part number off chart (26) (also part number for just about any web part ordering site)
Part Number (93410-24042-00)
Number needed for that page, (unless I figured out I was going to need more.)

clutch
26 93410-24042-00 1

transmission
4 93440-52009-00 1
7 93440-25084-00 3
14 99009-20400-00 1
16 93450-32042-00 1
20 93440-25084-00 3
26 99009-20400-00 1
28 278-17425-00-00 1
31 278-17424-01-00 1

TACHOMETER GEAR
3 93440-12051-00 1
5 93102-06254-00 1


Actually ordered not all inclusive, None of the local purchase made the list
99006-10600-00 5 Shift Cam – Fork 4, shift Pedal 1
99009-30400-00 1 Shift Cam – Fork 1
93410-24042-00 1 Clutch
13 93102-12321-00 OIL SEAL, SD-TYPE . 1 Shift shaft pedal

Plugs
26 90338-22021-00 PLUG, SPEC’’L SHAPE (371-18149-00) . .2 Shift Cam Fork

Gaskets One of each, unless you are planning on going back in a couple times, (Stator cover, and the small one on the outside the stator.

Crank Case Cover gaskets
2 1L9-15461-00-00
6 1L9-15455-01-00
15 1L9-15451-00-00

Oil Pump
13 1L9-13414-00-00

Electrical 2
Neutral Switch O-Ring "Local purchase" I have never been able to re-use this oring
11 93210-29196-00

Good luck! Print out the pages, so you can match up the parts, then make notes on the print outs, and go what you need. also track the other things you might need. Now that I am done, I just realized that I dont have Oil rings on any of my Oil drains. no wonder It seemed I torqued it on too tight. then the clutch shaft I did put on wrong, and noticed my mistake via the print out. (eventually) Remember one of the daily posters have posted the entire build breakdown, step by step, so you can always bring a laptop to the garage, with all the pics available. ThePsuedoMonkey did a photo diary.
http://www.xs400.com/media/albums/228/
Tobie

 

[AMR-XS400]

awesome thanks mate

 

[Liamthedevastator]

I'm definitely keen to use all new clips, though i'm sure ones that still have their spring would be fine to reuse. I just figure that if I'm going to take the bike down so far i might as well replace all the bits and pieces.

Thanks for the write up Arf, that was amazing. Great idea to make a list of all the parts related to what you need to replace then cut out what isn't necessary. I'm going to go and try to see if I can find the clips like you said

 

[Liamthedevastator]

Okay, so for a complete list of circlips on the 1977 XS400, ENGINE ONLY (this includes kick-starter assemblies), check this out: Circlip listing. I couldn't identify the genuine part numbers because I couldn't find a catalogue...

I hope this helps someone. I am just going to buy a huge kick of assorted circlips I think... more spares for later.

 

[Mekai]

I have looked EVERYWHERE for 93450-32042-00 Wich is a Circlip for the transmission.
CMS NL and bikebandit EVERYWHERE.
I lost mine during the rebuild. Does anyone know where to look?
Or do YOU have one in spare

 

[esmith87]

I found one awhile back. I just started calling and emailing every dealership I could find and eventually found a dealership who had one on the shelf. Sounds crazy, but I got what I needed

-Ethan

 

[Torbjorn]

Hello

I have also been searching everywhere for 93450-32042-00 without any success. I seem to have lost it during my rebuild or did it ever exist? Anyway, I went to my lokal bearing shop and they provided me with a SP30 circlip which I intended to cut into a half moon as the original. But does it have the correct dimensions? It is thinner than the other circlips that I have.

Will it work or should i keep on looking?

Torbjörn

 

[Mekai]

The one you are looking for is the small one on the drawing. It is also 2mm thick.

 

[Torbjorn]

Thanks Mekai!

Did you find one or did you had one manufactured? I measured the groove earlier and it is about 1,5 mm so I guess the thickness cant be bigger than that.

 

[Torbjorn]

Since it seemed impossibly to find a OEM part and my SP30 did not fit. I searched a different solution.

I bought a SW30 instead and cut it into a half cirkel. It fits perfect!!!

Torbjörn