Honda XR 400 Installation Manual

1
Honda XR 400 Installation Manual 1. Get a degree in Mechanical and
Electrical Engineering. (Just kidding! ) 2. Remove the seat, side
panels, and gas tank. If you are color blind or even think you might be a
little color blind, now is the time to get someone to assist you.
Successful installation of the kit requires good color recognition. You
want to go riding this weekend, don’t you? 3. Unplug the green and blue
taillight wires from the stock wiring harness, remove the taillight
lens, and remove …

2 7. Taillight
Installation: Install the Acerbis DOT taillight over the empty well left
in the stock fender using the two 5 x 20 mm bolts and 6 x 16 mm bolt
found in the parts bag. Position the taillight over the previous
taillight mounting well and transfer the hole locations for the top
mounting holes onto the fender with a felt pen or snap punch (Photo 3)
so that they are 3/8 of an inch above the edge of the taillight opening
as shown in Photo 3. Drill two 3/16 inch holes for the top mounts.
Attach the taillight using the top mounting screws, then pull the
license plate holder down toward the bottom of the fender so that the
taillight is pulled as horizontal as possible. Transfer drill a 1/4″
hole at the bottom mounting location with the taillight in this
position. When installing the bottom license plate mount bolt, make sure
to install the 6 x 16 mm bolt from the bottom up to minimize the
opportunity for the tire to grab it. Run the taillight wires along the
left frame rail using the stock wire clamps to support it….. 9 The
headlight bulb is a standard H4 halogen unit available at most
motorcycle shops and foreign auto supply houses. The XR 400 can only run
the 35/35 watt bulb without discharging the battery. Baja Designs can
rewind the stator to achieve up to 250 watts of lighting power for the
‘96 XR 400. 17. Rear Wiring Connections: You will now make all the
connections required to the wiring harness at the rear of the bike. Take
your time to do a neat job here so that you will have a reliable
lighting system. Refer to photographs to copy wiring layout. If you make
a mistake in the following steps, the worst that could happen is the
bike will catch fire and burn to the ground ( NOT) .

Download