RedRider,
If you do upgrade to a USD setup. I might be intereted in your stock 400 front end should you want to sell it. Looking for one to upgrade my '94 xr250.
Was going to originally upgrade w/ a complete inverted setup from a '93 CR500(fork, trees, brakes, frt. hub, but needs a new loop/spokes) that I was going to use. Also have the steering tube bearing cups from the cr that I was going to weld on the xr, so to use the bigger cr bottom bearing.(top bearing is same for both xr/cr) Was planning to cut the 250's bottom cup off & weld the 500's one on. Had the 500 upper bearing cup machined to fit the xr & then to be welded. The upper bearing cup would act as a spacer since the spacing between the upper & lower tripples on the 500 is wider.
The easier & more popular method of mounting would be to have a new steering post machined to fit the cr bottom clamp & the xr400 bottom bearing(xr250/400 top & bottom bearings are both same size) Some add spacers to take up the slack between the upper bearing & top clamp.
I pretty much gave up on it after a reality check that it was just an over kill for my type of riding(trails) I think the bigger xr400 tubing would be just fine.
Anyways, please let me know. Also, may concider swapping should you or anybody be interested.
Thanx! :) ....renny