RD400 Project

Aaron Russell · October 11, 2025, 12:58:03 AM

I got my RD400 about two years ago and has been a never ending project as I always want to add to it. I currently have it stripped back down for powder coat, some frame mods, and a couple more "upgrades" while its apart again. So I thought I might as well start a thread on it.

My setup on it was:
Triumph Street Triple / FZR Rotor Brake Setup
Accu Rearsets

HPI Ignition
Topend by Ted Boyko with light porting done and cut heads
Wossner Pistons
Mikuni VM30s
Wicked Motorsports Pipes

Aaron Russell · October 11, 2025, 01:10:29 AM

A couple issues I had with my build is that my kickstand would hit my pipes with or without the kickstand relocation kit and have had the kickstand drag a couple times.

Ive read about cutting off the stock point and welding it more forward on the frame, however I did not necessarily like this idea as once its there there would be no changing it especially after powder coat.

I took inspiration about having a bolt on mount made off a bike in the facebook group, this way if I need/want to change kickstand angle, height, etc I could simply replace the mount itself.

I then 3d printed to mock up and do a few changes and then off to sendcutsend to be made along with a few other things i needed done.

SoCal250 · October 11, 2025, 12:50:02 PM

Cool bike. Post up some more photos. Are you in So Cal?

Interesting kickstand solution. Cutting off the kickstand mounting tab and rewelding it forward is a common mod. When we used to do local "Wrench-fest" get togethers I remember watching Robakun reweld kickstand brackets in his garage in just a few minutes. I wish I could do it to mine but I can't because the PO powder coated my frame.

How long ago did you work with Boyko? How was your experience with him?

Aaron Russell · October 11, 2025, 04:30:33 PM

Quote from: SoCal250 on October 11, 2025, 12:50:02 PMCool bike. Post up some more photos. Are you in So Cal?

Interesting kickstand solution. Cutting off the kickstand mounting tab and rewelding it forward is a common mod. When we used to do local "Wrench-fest" get togethers I remember watching Robakun reweld kickstand brackets in his garage in just a few minutes. I wish I could do it to mine but I can't because the PO powder coated my frame.

How long ago did you work with Boyko? How was your experience with him?

Im in the central valley, I'll need to get more photos as I piece things back together.
Boyko did my topend about a year ago, he was great, sent me lots of photos as he moved along with everything. When he got to my cylinders he did everything quickly, sent them out, and got lucky with usps and got it the next day. His porting is more of a "blueprint" porting, I would definitely send more stuff when I get the chance.

SoCal250 · October 12, 2025, 01:14:08 PM

Quote from: Aaron Russell on October 11, 2025, 04:30:33 PM
Quote from: SoCal250 on October 11, 2025, 12:50:02 PMCool bike. Post up some more photos. Are you in So Cal?

Interesting kickstand solution. Cutting off the kickstand mounting tab and rewelding it forward is a common mod. When we used to do local "Wrench-fest" get togethers I remember watching Robakun reweld kickstand brackets in his garage in just a few minutes. I wish I could do it to mine but I can't because the PO powder coated my frame.

How long ago did you work with Boyko? How was your experience with him?

Im in the central valley, I'll need to get more photos as I piece things back together.
Boyko did my topend about a year ago, he was great, sent me lots of photos as he moved along with everything. When he got to my cylinders he did everything quickly, sent them out, and got lucky with usps and got it the next day. His porting is more of a "blueprint" porting, I would definitely send more stuff when I get the chance.

Good to know.

Thanks for the feedback on Ted. He's well known and has been around for a long time, but in the last few years I heard some somewhat negative comments about him from a long-time customer and was recommended to go elsewhere. I'm kind of thinking it may have just been one bad experience or a misunderstanding and not the current actual situation or general consensus.
I have a set of cylinders that I've been sitting on that I was planning to take to him since he's sort of local for boring and possible mild porting. As an alternative I was looking into Q&E over in Anaheim.

m in sc · October 12, 2025, 02:26:25 PM

are you going to weld a plate onto the side of the frame? we did this years ago using a triumph kickstand. I have one as well on my lightweight.

something to consider.

https://ebay.us/m/jGyYmz

Aaron Russell · October 12, 2025, 03:44:44 PM

Quote from: m in sc on October 12, 2025, 02:26:25 PMare you going to weld a plate onto the side of the frame? we did this years ago using a triumph kickstand. I have one as well on my lightweight.

something to consider.

https://ebay.us/m/jGyYmz

The plan was to notch the frame and weld in threaded bungs to bolt the mount to.

Aaron Russell · October 12, 2025, 03:49:39 PM

Just finished printing up a new tach/speedo mount for my new koso gauge.
My previous one was just a quick way to mount a single gauge.

SoCal250 · October 13, 2025, 11:29:15 PM

Quote from: SoCal250 on October 12, 2025, 01:14:08 PM
Quote from: Aaron Russell on October 11, 2025, 04:30:33 PM
Quote from: SoCal250 on October 11, 2025, 12:50:02 PMHow long ago did you work with Boyko? How was your experience with him?
I'm in the central valley, I'll need to get more photos as I piece things back together.
Boyko did my topend about a year ago, he was great, sent me lots of photos as he moved along with everything. When he got to my cylinders he did everything quickly, sent them out, and got lucky with usps and got it the next day. His porting is more of a "blueprint" porting, I would definitely send more stuff when I get the chance.
Good to know. Thanks for the feedback on Ted. He's well known and has been around for a long time, but in the last few years I heard some somewhat negative comments about him from a long-time customer and was recommended to go elsewhere. I'm kind of thinking it may have just been one bad experience or a misunderstanding and not the current actual situation or general consensus.
I have a set of cylinders that I've been sitting on that I was planning to take to him since he's sort of local for boring and possible mild porting. As an alternative I was looking into Q&E over in Anaheim.

Curious...how did you find Ted and end up using him since you're so far away from OC?

Aaron Russell · October 14, 2025, 11:07:34 PM

Quote from: SoCal250 on October 13, 2025, 11:29:15 PMCurious...how did you find Ted and end up using him since you're so far away from OC?

He was suggested to me by my father, I searched him up and he actively posts his work on social media and his website was clear, also him being in california was a big factor too. There isnt anybody local to me that I can go with small engine boring stuff so I had to ship stuff either way.

Aaron Russell · October 20, 2025, 11:28:38 PM

Yesterday I continued cutting off mounts and cut the old kickstand mount off. Still need to clean the cuts up more.
My billet mount came in as well as some other bits ill show as I get to it.

Has anybody cut off that center cross bar replacing it with a tube? I would guess I would want the tube welded in before cutting it off. I would like to remove it mostly to make it easier to clean from oils as oil get in it as well as the old footpeg mounts and it was a pain to clean.
Hopefully now my motor doesn't leak but it probably will continue to do whatever it pleases.

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RD400 Project