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.

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. 8. Rear Turn Signal Installation: Turn signal mounting requires that you drill a 3/8 inch hole in either side of the rear fender near where it meets the side panels. You can achieve a clean, durable installation using this mounting location. Mount the rear turn signals by drilling a 3/8 hole in the rear fender in the location shown in Photo 5, 3-3/4 inches back from the front edge (pointed tip of fender where it meets the side panel) and 2-3/4 ” up from the bottom edge.  If you desire the turn signals to be completely level, use a 3/8 inch diameter bolt and nut to sandwich two fender washers on the inside and outside of the fender.  Carefully heat the inside of the fender with a heat gun until you can pull the bolt down to horizontal (Photo 6) .  Reinstall turn signals. Run the left turn signal wires along with the taillight wiring forward along the left frame rail to the area just behind the airbox and above the fender.  Run the right turn signal wires forward along the right frame rail, and up to the same location behind the airbox. 9.  Brake Light Switch Installation: The latest XR 400 kit uses a hydraulic brake switch. This requires replacing the rear master cylinder banjo bolt with a specially made switch. Installing the switch requires bleeding the rear brake. If you do not feel competent bleeding your rear brake, please refer this job to a qualified mechanic as failure to do it correctly will make the brake inoperable.

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