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  1. The only place on the internet I could find really good and thorough suspension adj/set up info was here: http://owners.honda.com/assets/OWNERLINK/model/own_man/powersports/2004/2004_XR400R.pdf (Pages 95-106) Finally got my XR400 set up the way I like it. Handles so much better, especially heading into turns, and rides so much smoother.
  2. Hi all. Just bought a pumper carb for my '02 (or is it '01, my memory is shit) XR400R. I have a Big Gun exhaust, and I rejetted it based on recommendations here. Do I use the same jets for the pumper carb, or do I need to re-jet again?
  3. Hello, I’m new here. 1st post. I bought a street-legal XR400R 2 years ago. It’s always hard to start cold, but once warm starts first or second kick. This weekend it gave me some trouble starting after fully warmed up on the trail after a short stop. I’m no mechanic. Could this indicate that I may need a valve adjustment? It runs great otherwise.
  4. So was putting a new gasket on my float bowl and found this on the sub frame. It looks like a chain roller, but why is it right there? Is it a spare from the factory? Just thought it was odd, what do y’all think? *edit I know the subframe screw is out, had the subframe off to take out the carb
  5. Hi, new to forum thanks for any help. picked up a 2003 xr400 that was supposed to be full complete rebuild,engine, suspension. I’ve read 20hrs of threads! went threw bike found some problems incomplete routings, broke valve cover bolts etc. Repairs complete took her out for a spin. Bog and misfire, loud valves. Took bike in, cleaned carb and set floats. Adjusted valves and checked carb boot. Ran better, still not happy. So New pumper carb, oem coil , new plug, adjust valves, smoke test for leaks. Bike rips but still misfire/stutter low rpm , sounds like rrrrrrrrrrrrPPrrrrrrrrrrPPrrrrrrr. Random intake pop also. Then off idle more like stumble stutter, light throttle. So odd. Installed o2 bung and setup wideband. Was lean 17-18afr at idle 15wot. Went up jet size . Btw carbs came off 10 times not fun. So now 13 AFR at idle 11-12 wot. Better but still misfire and stutter. Stator test, ok. New oem coil -good. Check wires ok. only thing I can think of CDI or burnt valve but I pulled head and it looked fine . I’m lost any help I would be great full. Bike rips other then this plenty of power. Does also have aftermarket cdi, making me wonder but I’m lost
  6. So I have to rebuild my 01 xr 400 as I blew the countershaft and I was given a parts list from my mechanic and was wondering where if possible I could save a few dollars. Major parts that are adding up are the OEM complete gasket set 300+ Canadian, OEM timing chain (144), outter clutch basket (400+) countershaft (177) ring set (78) oem tensioner (110) and possibly a kickidler gear (130) So basically am I looking for recommendations if I should stick to oem for these parts because I can get the pro-x gasket set for 150 and have someone make a gear for the basket at 200ish. I've seen the possibility of using a oem 2002-2003 crf 450r timing (60) or aftermarket standard chain for about the same and found cam chain tensioner new on ebay for 20 dollars but my current one worked fine so unsure if I should replace it. Any feed back is appreciated!
  7. Bought as a no start. Cleaned carb. Intake /exhaust valves don’t leak air at TDC with leakdown test , does through the rings though but with how hard only 10-30psi turns the crank when trying to hold it with a breaker bar that doesn’t surprise me(My air compressor takes forever and I could only get it up to 40psi.) All electrics test fine replaced cdi with ricks cdi box . Before cdi box with oem one it backfired 2 times in literally 300 kicks . With new cdi , 4 backfires in 25 kicks. Then compression died so assuming I flooded it. Fuel gets to spark plug obviously. After searching this website for no start backfire( I’ve seen multiple fixes for people , saying valve springs, cdi box, and stator . Has anyone here had a stator be the problem while the multimeter tests were fine? I’m not trying to replace everything lol (or a sheared woodruff key)
  8. Hello.. I had bought and put together a ac to dc converter/regulator from amazon. So I could use a led light to replace the old shitty one. I put the led bulb in and it burnt out. Then I found out i need to wire up a battery to make it 12v. But How would I wire it so it charges while the bike is running? I dont want to have to charge it ever. Just need to know how to wire it to the stator or whatever.
  9. Looking for a wiring diagram to make matters simple, I know its not very complicated, and given enough time could figure it out without letting too much smoke out of the wires. Thanks in advance
  10. Hello all I just recently picked up a 2002 XR400R from a fellow up in madison Wi for $2300. Here is the link to the bike running. I already adjusted the Valves to .05 and .04 as per manual but I still hear a tick after the bike warms up for a bit, when its cold you can't hear it. Also when you rev the bike up you can't hear it tick really. ( skip to 0:30 to hear the rev ) Did i adjust my valves poorly? Or does the noise sound like its the cam timing chain ticking from either being stretched out or the cam chain tensioner being worn out. Let me know what you guys hear.
  11. Hey folks! I hope you're all doing well. I have my XR400R for a relatively short period of time and have only done relatively short rides with it. However, I'm planning a trip from Portugal to Morocco on what could be a 5000 kilometers roundtrip. Considering an in depth maintenance (oil change, new sprockets, tyres, break pads, chain, carb clean, etc) what do you think it is worth considering taking along as spare parts or for maintenance? The bike has the Gordon's mods and a bigger tank - I think everything else is stock. I plan to do mostly offroad. The terrain will have everything from dunes to river beds, etc. I'm a bit worried that the bike can't deal well with such long distances or that there are parts that will wear fast.
  12. Hey fellas, I have an XR 400 and it is in dire need of an oil change. I ordered some oil, ill attack a pic of it below. My worry is that it ester is one of the chemicals used in it, which will cause the clutch plates to slip. Engine oil and clutch oil are shared. Does anyone know if the ester used will cause the clutch plates to slip? Thanks a lot guys --Nico
  13. Hello everyone, just purchased a 2004 XR400R pretty much stock with very little use. I have known the bike / owner for many years, just took it home and will start servicing it. I know I am late to the party ... when most people is getting a bike with the "magic button" I get and old kicker! 🙂 In the past owned and maintained a XR650L and also a XR250R ... hence not a total noob! Also ride / maintain BMW airheads. I am sure I will ask some questions when I get stuck. Godspeed.
  14. So i've had my xr400 for a while and its been a blast but it has always been a pain to start. I finally want to get the jetting dialed in for my location (western washington sea level). With an FMF exhaust, uni filter and no snorkel, I'm assuming a good place to start it 58-62 pilot and 158-162 main. When I pulled my carb I have a 58 pilot and a 182 main! Am I dealing with something different? I was thinking maybe its not 400cc anymore but I'm not sure why the main is so big. I was thinking about just making the pilot bigger but the main jet size is really throwing me off on where to start. Any idea why my main would be so big? Thanks guys
  15. Hi all, I am heading to pick up a 2000 Honda XR400R tomorrow with the intentions of making the bike street legal. the bike has some upgrades such as FMF power core exhaust, Hotcams stage one camshaft upgrade, stiffer shock and fork springs and a mikuni pumper carby. Will these make the bike unable to be registered? other than that the bike is pretty much stock. Other than indicators, mirrors and tires, what will I need to do to the bike to make it street legal for use in Tasmania, Australia? Any help is greatly appreciated. Thanks
  16. I'm in the process of cleaning/re-jetting and generally servicing the carb on my much loved 1999 XR400. Ballards, XRsOnly and probably others sell choke plates with two little holes in them. Does anyone have experience of such plates? What is the benefit of the two little holes? Is it worth it?
  17. Hi I am in need of replacement kickstart shaft for my 2002 Xr400. As I’m looking online for a used replacement, I’m realizing the only one available is from a 1998 model xr400. I noticed that the older kickstart shaft is slightly different then the 2002 (after 1998 the kickstart shaft on the xr400s had a bigger washer by 2mm along with a slightly different shaft diameter where the wider washer sits against the shaft) I have heard that the newer ones will work on an older model if you have the crank case machined to accommodate the bigger washer/ shaft. Does anyone know how it would fit vise versa? My question is will the 1998 kickstart shaft fit on a 2002 model? Any info is appreciated, thank you
  18. Hello all, I'm new here. Bought a XR400 a couple of years ago and now just getting around to the re-build. The bike is stripped and I'm starting to re-assemble. My question is can someone please advise how/where exactly I can run 12v into the bike to test the loom and sort the electrics. I've have a new headlight unit and I want to add an indicator kit but I can't start the bike as I have no outdoor space to work on it. Any help would be greatly appreciated. I do have the Haynes manual but electrics are not my strong point. Thanks, John.
  19. Im stumped,, my 1999 XR 400 is lean,, im up to a 165 main jet and plug tip is still white and the bike runs lean, holding the throttle wide open then backing off it then dies until I roll back on the throttle ! I'm using a # 62 primary jet and I have put needle clip to the 4th position(richer)bike has stock air box, Foam UNI air filter,Yosh pipe and Big Gun headers .. In most forums I read that a 165 main should be way big enough, Evan with-a modified air box,, mine is stock !! Also checked intake manifold for cracks,, none to be seen
  20. Having just bought a 2002 XR400R a few weeks ago I'll be updating a few things needed, giving it a proper check-up, and eventually clothing it in the splendid black and gold livery of my favorite Formula 1 team - Lotus. First up was fitting the correct, properly fitting gas cap onto the Clarke gas tank. Super sexy stuff, I know. Next enthralling addition was a $20 Honda lightbulb so I can see...as it turns out, only about a foot in front of the bike at night. Last thing for now was the IMS Super Stock foot pegs so my get-away-sticks have a more solid, more comfortable base to fall off of when I crash in the sand. Stay tuned for more. Or don't. Whatever. You do you, Nancy.
  21. Hi forum, I'm now rebuilding my shock 2nd time. First time was last winter when I just got the bike (low milage) and wanted to check everything. I did the shim stack mod (from reading a lot od info here), changed the bladder and filled up with Motul VI400 which was available. Later I found out this is only 2,5W and not 5W as recommended by Honda. The result was actually fine but a bit soft even with comp and rebound dialed all in. Now after 1 year and 1600 km (1000 miles) I found the shock leaking in my garage and have taken it all apart again. What I found was a bit surprising. Oil colour has changed from slight pink to greenish - and with a lot of grey sediments. A LOT... What the h... after that short time? Is that alu or teflon particles? Or both? And so much after so little time? Strange... And what about the change of colour? Questions: Should I keep the shim stack mod and find a new 5W oil? (bit difficult to find - and expensive incl. post) Or should I keep the 2,5 Motul (I still have some left) and change the shims more or less back to original? Does the the shock work best with 5W or 2,5W? Will it more likely leak with 2,5 than 5W oil? (I have ordered new oil seal, O-rings and piston band) PS: I'm just trail riding for fun. My weight is 95 kg with all gear. Shock spring is original, max compressed to 10cm sag, fork springs harder and fork had shim mod)
  22. Hello! I am removing an old enduro/street legal kit for my 1997 XR400 and upgrading to LED blinkers and an LED front light - i want to keep the stock rear fender with the brake light/two filament bulb because it works. I am doing this with a Baja Designs Squadron Pro MC LED Race headlight, the Baja designs REC/REG and fuse, Tusk LED/Harness/blinker kit, and a 12V AGM battery. Here is my modified wiring diagram - with the Stock diagram for reference. Was hoping some of you wiring gurus (or XR guys) would look over my drawing and see if you can find any issues or have suggestions before I start cutting things up. :) Thanks!
  23. Hi! Does anyone know how many ohms the (black+red & brown) wired must have? Mine is 600 omhs,I think it is too much but I have spark , it is repared and I DONT REALLY WANT TO GET THE CDI DAMAGED ! THANKS
  24. Hi All, So i have my XR400 for about 5 years now, i ride it almost every weekend and never had any issues with it except the side stand breaking away from the frame. i change the oil every 1,000km and check valves every 5,000km but they never need adjusting. I want to update/upgrade to another Honda but i dont see anything that ticks all the boxes like the XR400 does, what do you guys think ? I like the CRF450X but i have heard the top ends and gearboxes dont last very long, is this true? I also like the CRF450L but its fuel injected and im not a fan of FI systems. If i could buy a new XR400 i would but i cant and one day i will need a replacement for my XR so the question is what would it be ?
  25. Anyone XR400's out there using Antigravity batts? Its almost small enough to fit in the Acerbis rear fender light hole.
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