XR400R Setups
XR400R Setup and Modifications. The following modification and setup information is related to the 1996, 1997 and 1998 Honda XR400R. However, most of the information can be applied to newer model year XR400Rs. This information is meant as a reference only.
This content is from the original Unofficial Honda XR Website by Jeremy Hansen. Jeremy asked that this content be hosted on 4Strokes.com and kept available for all in which to benefit. We were sorry to see the Unofficial Honda XR Website go away but happy to fulfill Jeremy's request.
| Owner | Location / Altitude | Carburetion | Exhaust | Tires | Engine | Accessories | Drive Train |
|---|---|---|---|---|---|---|---|
| Brett | Utah / 4500' | 155 Main, 62 Pilot, reduced float travel, dual taper needle installed in 2nd position | Thumper Racing baffle | Front stock, rear Michelin MP-11 130/80 - 18 | Stock | Moose rear fender bag, Cat Eye CC-AT100 cycle computer (with altimeter), Garmin GPS II | Front sprocket changed from stock 15 tooth to a smaller 14 tooth sprocket |
| Chris | Utah / 4500' | 155 Main, 60 Pilot, Dual-taper needle installed in #2 position | Thumper Racing baffle | Front stock, rear Michelin MP-11 130/80 - 18 | Stock | Cat Eye model CC-AT100 cycling computer | Stock |
| Jeff | Utah / 4500' | 158 Main, 62 Pilot Jet, custom sanded needle installed in the #2 position | Stock baffle removed entirely | Stock | Stock | None | Stock |
| Grant Broadbent | Upper North Island, New Zealand / 0-500 Meters (0-1600') | Stock jetting for no-baffle, dropped float level 1mm, more work to do here | Stock exhaust without baffle | Front Bridgestone M49, rear Bridgestone M60 | Stock | Acerbis front fender | Stock US Spec: 15/45, O-ring chain |
| Mark Boyd | Boulder, Colorado | Dual taper needle in #2 position, 158 Main (baffle removed), 155 Main (Thumper insert) 62 Pilot, K&N air filter | Stock head-pipe and muffler - Thumper insert for Trail and removed for MX | Stock | Stock | White Brothers skid plate, Renthal bars | Stock |
| Matthew Swap | Washington State / 0-1000' | Stock jetting, float 14mm | Stock exhaust with baffle removed. Intake baffle also removed | Stock tires but will probably change to Dunlop when they wear out | Stock | Devol skid plate and frame guards | Stock |
| Jon Markuson | Minnesota / 900' | 160 main, 60 pilot, dual taper needle in 3rd slot, float to Honda specs | Homemade baffle insert | Pirelli MT-21 front and rear, 130-90x18 and 90-90x21 | Stock | Baja Designs dual sport kit, Acerbis hand guards & mirror | Stock |
| Jeff Interlicchia | Riverside, CA / 1500' | 160 main, 62 pilot, dual taper needle on 3rd slot, carb slide mod, XR600 K&N air filter | Thumper racing baffle, welds in head pipe ground | DOT approved Pirelli & Dunlop for dual sport | Stock | Baja Designs dual sport kit, Pro Circuit suspension, Scotts steering stabilizer | Stock |
| Steve Turner | Dallas, Texas | 175 Main, dual taper needle in middle position, 65 pilot | Yoshimura - YRD pipe | Front & rear Metzler Unicross tires, Excel rims | White Bros Power Up kit , stock bore 10.8.1 JE Piston, Cam, Rev-kit, flowed head, Barnett clutch kit | Race Tech revalve shock, Gold Valve in forks, IMS pegs, shifter, gas tank, Ceet seat Cover | Stock |
| Mark Smith | Portola Valley, California / 1000' | 160 main, 60 pilot, dual taper needle in #3 position, float set to 14.5mm | Stock | Stock | Stock | None | Stock |
| B. Rob | 50 meters | 62 main | baffle removed | Dunlop front & rear | Stock | None | 45 tooth rear sprocket |
| Greg Winters | Ridgecrest, CA / 1900' | Cut slide, 162 main, 65 pilot, stock needle in 3rd clip, Honda float mod | stock exhaust, Krizman baffle | Varies with terrain | IMS 440 kit, IMS head mods, removed stock air filter cage & baffle, HD clutch springs | Race Tech gold valve front and rear, HD front springs | Stock 15/45 |
| Tom Young | Denver, CO / 7000-10,000' | 155 main, 62 pilot, cut 1mm from front of slide, K&N filter | Removed baffle | Stock | Stock | None | Stock |
| Doug May | N/A | Baffle removed | Removed exhaust baffle | Dunlop 990 rear, Bridgestone M25 front | Stock | Aluminum bars, Acerbis hand guards, Pro-grip grips, brake light, home made oil line guard | Race Tech 4.2 fork springs, Factory Connection re-valved shock |
| Brad Schwartz | N/A | XR600R carb with 165 main & 65 pilot | Yoshimura pipe (no HP difference but sounds good) | Meltzer's front & rear | 440 kit, head flowed, valves reground, still needs a different cam (mods raised 9 HP on dyno) | Big tank for desert, aluminum bars, made street legal | Stock gearing for Utah riding, 52 tooth rear or so for mountains and trees |
| Jeff | Washington / 1000-4500' | Needle position to #2, removed baffle | Supertrapp with 5 discs | Stock | Stock | None | 13 tooth front sprocket, stock rear |
| Curtis Emmerson | NW Washington / 0-4300' | Rised needle 2 notches, moved vent tubes up out off the way | Supertrapp silencer w/5 or 6 discs | Michelins front & rear | Stock | Renthal Jimmy Button bars, bark busters, Acerbis frame guards | 1 tooth smaller primary for all but my desert races |
| Josh Huntsin | GV, CA / 2000' | 65 pilot, removed snorkel and backfire screen | Baffle removed | Pirelli MT21 front, Kenda K760 120/18 rear | Stock | Renthal Jeremy McGrath bars, bark busters, Works Conn. skid plate | Chain |
| Stephen Swap | Bothee Washington State / 0' | Strode Eng mod, slide mod, stock needle put in #3 clip, float height set, 152 main, 53-55 pilot | Baffle removed | Stock | Stock | None | Stock |
| Mad Man Johnson | Berlin, NH / 900' | 40mm Mikuni off of a Polaris snowmobile engine | Yoshi | Stock | 12:1 piston, head work, valves, Sunoco race fuel, cam, opened up airbox, dyno'd at 62.2 HP | None | 1 tooth taller on front sprocket |
| Eric Blattert | Indianapolis, Indiana / 500-750' | Leaned it out a bit from stock | Pro Circuit PC4H w/no baffle, White Bros oversize head pipe | Dunlop 737 front, Dunlop 752 rear | White Bros Cam & high comp. piston, VP race fuel | CR250 fenders, Race Tech fork & shock springs & G Valves, Renthal bars, Acerbis hand guards | Renthal 14 tooth front, Renthal 45 tooth rear, gold o-ring chain from Moose |
| Mike Smith | Ketchum, Idaho / 6000' | Smaller main & pilot, dropped needle l notch | Baffle removed | Stock | Stock | Baja Designs DS kit, Acerbis Rally handguards | Dropped 1 tooth on front |
| Caleb Stewart | New Salem, NC | Leaner jetting | Stock | Stock | Stock | Acerbis bark busters | Stock |
| Gordon Hogan | Ensenada, Baja CA | Dual taper needle in middle | Thumper Racing insert | Stock | Stock | None | Stock |
| John Bongiovanni | Denver / 5280 | K&N air filter | Baffle removed | Metzler Unicross front & rear, 120/90-18 & 90/90-21 | Stock | Devol guards & skid plate, Renthal bars, Race Tech Gold valves front & rear | Stock |
| N/A | Europe / 2000-3000' | 165 main, 62 pilot but still too lean for extended high speed | Thumper Racing insert | Michelin AP 11 | HRC Power Up Kit w/ shorter primary drive | Braking Over sized discs front and rear | 14/45 |
| Derek Smith '97 XR400R | W. Washington / 0-2500' | Stock jets, dual taper needle on 3rd clip, pilot screw 3 turns out, float at 14.5mm, removed intake baffle, Uni filter | Vortip Racing baffle | Stock for now but will replace with M21's for dual sport | Stock | Hardcore Racing fork covers. Acerbis front disk cover, Rally hand & frame guards. Renthal bars & grips. Moose skid plate & rear fender bag. | Front 14 tooth (1 off stock) sprocket, rear stock |
| Carlos F. | Asuncion, Paraguay / 450 meters | 165 main, 65 pilot, needle in position #2, K&N air filter | Baffle removed, homemade one replaced | Stock | Stock | Acerbis frame & disk guards | Renthal bars, 15/45 Renthal sprockets & chain |
| Dave F. | Mission Viejo, California | 60/160 & needle | Supertrapp EAR | Stock | Stock | Acerbis dual sport, IMS 4 gal tank, DG skid plate | 43 rear sprocket |
| Paul Kellogg | Marin County California | HRC needle with specified jetting | Baffle removed | Stock now but will replace with Dunlop K755 & Michelin M12 | Stock | Works Conn. frame guards, MSR skid plate, Acerbis Rally hand guards, Renthal bars, Race Tech Gold Valves | Stock |
| Brett Jamieson | N/A | 160 main, 55 pilot, HRC Power Up needle in stock position, K&N air filter | Baffle removed | Trelleborg T744/754 Tenmaster 110/100-18, Pirelli MT21 front | Stock | Moose skid plate, Acerbis Rally hand guards, Renthal bars, IMS oil line guard & shark fin, Devol oil filter & frame guards, Acerbis front disc guard, magnetic oil drain plug | Renthal 15/47 - 14/45 DID 520V chain |
| Bryan Kennedy | Orono, Maine | Tapered needle | White Bros Magaloy with an open end cap & stoke header | Dunlop 755 front, Dunlop 752 rear | Stock | Acerbis RM 250 front number plate | Stock |
| Evan Matzner | Palm Springs / 0' | Jet kit from Baja Designs | Thumper Racing insert | Stock | Stock | General Baja Designs upgrades | Stock |
| Forrest Allen | San Diego, CA / 1000' | 68 pilot,155 main, needle #3 position, float 14mm (19mm max travel) | Thumper insert | Front stock Dunlop, rear Pirelli MT-21 | Stock | Devol lowering link, shock re-valved, stiffer front springs, Baja Designs kit, Scott's damper | Stock |
| Stuart | Tulsa, OK / 750' | 152 main, 55 pilot, 14.5 mm float height, clip position #3, Strode slide mod, Uni filter | Thumper insert, ceramic coated pipe & header | Stock | Stock | Devol frame guards, Factory Connection shock mod, burly pegs, Acerbis hand guards, Answer Alumilite bars | Stock |
| Charles Mann | Utah / 4500' | 155 main, 60 pilot, needle 2nd position, intake baffle removed | IMS insert | Front stock, rear MP-11 | Stock | IMS oil line guard, Moose rear fender bag | 14 tooth front sprocket |
| Rusty Shaffer | Raleigh NC / 0' | Removed intake baffle & backfire screen | Baffle removed | Stock | White bros. heavy duty clutch springs | IMS oil line guard, Answer Pro taper bars | Stock |
| Perry Sconzert | Liverpool, NY / 0' | Carb slide milled to HRC specs, Twin Air filter | FMF Megamax using all disks | Front 80/100 - Dunlop 752F, rear 110/100 - Dunlop 752 | Moose / K&P wire mesh oil filter, K&N filter on crankcase breather tube | Renthal bars, Acerbis Rally guards, Pro-Grip grips, Magura clutch perch & lever (from ATK), Moose shifter | Renthal sprockets, Tsubaki o-ring chain |
| Robert Mondshine | Houston, TX / 100' | 160 main, 62 pilot, stock needle & clip, stock float height but shortened 6mm to keep from sputtering on G-outs, air snorkel removed | White Bros head pipe, stock muffler with baffle removed | Front Dunlop K490 80/100, rear Dunlop K752 110/100 | Stock | Self-made street legal kit, Maier alum hand guards w/plastic covers, Yamaha mech speedo head & Cat Eye speedo | Front 15 tooth, rear 48 tooth, RK o-ring chain |
| Alvaro González | Guatema City, Guatemala / 4000-8000' | HRC Power Up kit, main needle, aftermarket air filter | FMF Comp, no spark arrestor | Front Dunlop 752, rear K490 | HRC Power Up kit | Answer Pro Taper bars, skid plate, Acerbis hand guards, Devol front disk guard, Works Conn. frame guards, clear protector to maintain graphics | Stock |
| Dick West | Auburn / Grass Valley, CA / 2500-4500' Donnieville / 4-9000' | 1 up on pilot, 1 down on main, dual taper needle on 3rd clip, float 2mm richer than stock settings | Baffle removed | Michelin tires front & back | Stock | A-Loop suspension | 14 tooth countershaft sprocket |
| Eddy | Singapore | HRC setting | baffle remove | Stock | Stock | PHS bar & skid plate, Devol disc guards, UFO KLX headlight, digital meter | RK o-ring chain, 15 tooth front sprocket, 43 tooth rear |
| Derek Gillette '97 XR400R | So. Cal / 0-5000' | Stock | IMS spark arrester | Stock | Stock | MSR Baja kit | Stock |
| Eric Bizon | Wilsonville, OR | 162 main jet | White Bros. Megalloy, oversized header & silencer | Stock | White Bros cam | IMS 4 gallon fuel tank, Acerbis Rally brush guards, Answer Pro Taper bars | Stock |
| N/A | Melbourne, Australia / 0-1000' | Needle dropped 1 notch, both pilot & main jet one size smaller | Baffle removed | Front Metzler MC4, rear Dunlop 737 | Stock | Bark busters, Whipps Alloy bash plate, grease nipples on rear linkage | 15 tooth front sprocket, 45 tooth rear sprocket, RK o-ring chain |
| Eric Hunter | Montgomery, Alabama / 325' | 34mm Mikuni carb kit, CR Quik-Turn throttle, airbox screen removed, top cover off | FMF Mega-Max exhaust system | Rear Dunlop K752, front Dunlop K490 | Ports cleaned, matched & polished | Acerbis hand guards, N-Style graphics, removed headlight for better oil cooler flow, Renthal bars & grips, seat cover, XR250 fender bag | 46 tooth rear sprocket, stock front sprocket, Tsubaki chain |
| Art Edmund | Singapore | N/A | Supertrapp with 6 discs | Stock | Stock | FMF seat cover, Answer Pro Taper bars | 14/45 stock |
| Dennis Cramer | Rochester, NY / 500-1500' | 155 main, 58 pilot, Twin Air air filter | Thumper insert | Metzler Unicross, Pirelli MT21 | Stock | Aloop suspension, Works Conn skid plate & guards, Moose Shark Fin, Acerbis Rally guards, PC graphics, MSR DS kit, Renthal bars & grips, Barnett clutch | Stock |
| Dave Pickett | 200-7000' | HRC factory needle from the power up kit, -1 on main, +1 on pilot, pilot screw 2 1/4 turns out, twin air filter, snorkel removed | Thumper Racing insert | Front Dunlop K139, rear K695, Metzler heavy duty tubes | Stock | Answer Pro Taper bars, Baja Designs dual sport kit, Devol oil filter guard, IMS oil line guard & shark fin | -1 tooth on countershaft sprocket |
| Stan Simpson | San Antonio, Texas / 650-2400' | Carb bored 1.8mm, new float system, 162 main, 62 pilot, power up needle in #2, twin air filter | Stock header, Krizman type s/a welded to front of stock muffler, c/f Kevlar oval tube w/28mm core & A-Loop glass core kit | Front K139 for rocks with 12 PSI, rear 695 or 737 with 13-14 PSI | Bored & stroked to 444cc's w/ 10.7:1 comp. Stock cam w/ new rockers & valve springs. Rev limiter mod to reduce max RPM to 8800. | WER damper, frame, subframe & foot peg gussets, welded on skid plate, XR600 forks w/Burleson internals | Power up kit primary w/ Transalp clutch springs, Silkolene synthetic 20-50 |
| Jason Moody | Toledo, OH | 162 main, 68 pilot, dual taper needle #2 position, 19mm float height, t-vents, Twin Air filter | Baffle removed | Dunlop 752's front & rear | Stock | Acerbis Rally hands guards & HT55 CR hi-bend bars, Race Tech Gold Valves, stiffer fork springs | Front stock, rear 46 tooth |
| B. Chase | 5000-9000' | 158 main, 60 pilot, pilot screw 2.5 turns out | removed stock baffle | Stock | Stock | Stock | 15 front sprocket |
| Bill C. | Wisconsin / 800' | 160 main, 62 pilot, dual taper needle in center, 14.5mm float height | Thumper insert | Dunlop 752's front & rear for soft terrain | Stock | Ohlins shock, 0.46 kg/mm fork springs | 13 tooth front sprocket |
| Aaron Negherbon | N California / 0-2500' | WB flat slide mod | Pro Circuit (ISDE) with WB head pipe | Excels rims, Talon hubs, Buchanan spokes, Dunlop tires | WB 406, 3 way on head, split & match, JE piston | Ohlins shock, Marzocchi fork, Braking rotors, CR plastic, Atomic 22 bolts, Renthal bars, braided lines | 44 tooth Afam rear sprocket |
| Aaron Bailey | Seattle, WA | Stock | Baffle removed | front stock, rear Dunlop 755 | Stock | One industries seat & graphics kit, Answer Alumalite bars | Stock |
| Barry Dohrman | So Cal / 0-5000' | K&N filter | Stock head pipe, FMF Megamax | Stock Dunlop's | Stock | Pro Tapers, Applied top triple clamp, Baja Designs Street Legal kit, IMS big tank, wide pegs, W.C. bash plate | Stock |
| Jim Johnson | Brigham, Utah / 4220' | N/A | baffle removed | Front stock, rear Metzeler Uni-Cross | Stock | Renthal Bars, bark busters, Acerbis front disc guard, Moose magnetic drain plug | 13 tooth front & 52 tooth rear sprocket |
| Tony Pellegrino | N/A | Lowered stock needle 1 position, 1 size leaner main, removed 0.5mm from slide | Removed stock baffle, installed IMS spark arrester | IRC front & rear | Stock | Clutch springs, front & rear suspension | 14 tooth front sprocket |
| Dave Howard | UK / 0' | Stock | Tapered headers, Supertrapp | Pirelli tires | White Bros big bore kit, HD clutch springs | CR250 USD forks, rear linkage shortened to increase ride height | 13/50 Renthal o-ring |
| Steve Smith | MI / 500-1900' | 158 main, 65 pilot, float mod, dual taper needle 3rd slot, Uni filter, removed snorkel | Thumper Racing Baffle | Dunlop K990 front & 110\100 rear | White Bros clutch springs | Race Tech fork springs, Acerbis bark busters, Maier fork guards, MI title street legal | 14 tooth front, 45 tooth rear |
| Dwight Burch | Masonville, CO / 5500-11,000' | 148 main, 58 pilot, dual taper needle 2nd from top | Thumper Racing insert | Stock | Stock | Stock | 14 tooth front sprocket |
| Keny Richo | So. Cal. / 0-9000' | Stock pilot, 165 main, Honda comp needle # 16012-NKK-000 , teed vent tubes, Uni filter, airbox baffle removed | Stock w/ baffle removed | Stock front, IRC 130/80 rear | Stock | Acerbis brush, frame & front disc guards. Devol chain guard, IMS oil line cover & shark fin, Renthal desert high bars, Pro grips, WB skid plate, Chase Harper fear fender bag | Stock front, PBI 43 tooth rear sprocket |
| N/A | Illinois / 600-1000' | K&N air filter | Thumper insert | Front Dunlop K990, rear Dunlop K755 | Barnett clutch springs | Baja Designs kit (titled), Renthal CR bars cut to 30", Acerbis hand guards, Yamaha XT speedo, Moose rear fender bag | Stock |
| Trail Bike | London, UK / 0' | Stock jets, leaner on the clip, limited float travel | Baffle removed | Enduro tires | Stock | ICO Rally 2, Desert Fox bash plate, MSR handguards, Racing Parts twin halogens | Stock |
| Mark Chan | N/A | Stock | Baffle removed | Excel rims, Talon hubs, Dunlop 707 rear & 695 front | Head skimmed by 1mm | Stock | Front 13 tooth, rear 51 tooth |
| Darren Ravenscroft | Manchester, UK | N/A | Supertrapp with 4 disks | Stock rims & tires, set of 17" wide rims on talon hubs with Michelin cut slicks | Stock | Acerbis plastic, Renthal bars | Stock front sprocket, stock wheels 48 tooth rear, 17" wheels 44 tooth rear |
| Jack | Washington State / 0-2500' | Stock | Removed baffle | Michelin S12 front & rear | Stock | Devol skid plate, Acerbis hand guards, One Industries seat cover & graphics, fork springs | 14 front, 47 rear, Renthal sprockets |
This content is from the original Unofficial Honda XR Website by Jeremy Hansen. Jeremy asked that this content be hosted on 4Strokes.com and kept available for all in which to benefit. We were sorry to see the Unofficial Honda XR Website go away but happy to fulfill Jeremy's request.