Passenger Peg Install on XR400R Dirt Bike by b

Passenger Peg Install on XR400R Dirt Bike by b_king on 4Strokes.com

4Strokes.com Honda Technical: Passenger Pegs Installation on an XR400R By Robb Nelson (b_king)
Some people that dual sport their dirt bikes may also want to carry a passenger, or at least I do. There are clamp-on and bolt-on type passenger pegs available. Obviously the clamp-on type would not require additional brackets if there is a place on the subframe or frame rail to mount them. I obtained a good used set of passenger pegs from an XR650L, and these required brackets to be welded to the subframe of my XR400R, as shown below.
Flat steel stock for brackets	Bracket welded to subframe	Close-up of passenger peg	Passenger pegs installed
Here is everything used for my passenger peg installation: Scrap piece of steel (I used something fairly thick) Passenger pegs (I got a used set from an XR650L) Mig or arc welder and moderate welding skills (this was my first time) Drill, bits, and a tap the size of the bolts used (tap is optional) Primer and paint the color of the frame Here are the steps I used for my passenger peg installation: The first step is to sand the area of application. On the subframe of my bike, just below the elbow in the frame, is where I mounted my passenger pegs. Next, I found some steel to use as mounting brackets (x2). I used some scrap lying around, it was around 9 Gauge. Strip off any paint and clean the metal of any grease and oil. I planned out my brackets by making any necessary measurements and hole markings. It may be easier to drill all necessary mounting holes in the bracket before cutting them out. The holes required for my XR650L passenger pegs were 5/16" threaded. A few options for mounting the pegs are: 1. Drill bolt holes for clearance fit and use nuts on backside. 2. Drill and tap holes to the thread size and pitch of the mounting bolts. (I went with this method) 3. Drill bolt holes for clearance fit and spot-weld nuts to the inside of the brackets. I cut the mounting brackets to their final size before welding. Mine turned out to be 1" x 4". Now comes the fun part. After prepping both surfaces by sanding and cleaning, you could either tack weld or use a clamp to hold the brackets on the rail. Weld the brackets, both on the front and back side (as shown here). Don't forget to get the top and bottom as well. My welds are not that nice looking, as this was my first time ever using a mig welder. Clean up the welds with a die grinder and stones. Drill the passenger peg mounting holes if you have not already done so in step 3. Prime and paint the area to avoid rust and corrosion, and so it looks good. Install the passenger pegs with the bolts of choice. Mine were 5/16" Fine thread stainless steel bolts and nuts. It is also a good idea to use locknuts and/or thread locking compound. A word of caution: You must keep in mind that the weight of a second rider will put more stress on the suspension, motor and drive-train, so extreme caution should always be used when riding with a passenger.
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