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Hopefully you got your bike jetted and figured out by now. But in case you haven’t, I just had he same problem with my 99 XR400. Plug was black (indicating too rich), but all other indicators were saying too lean (backfiring/popping, hard to start, rough idle, better on choke, Gordon’s mods complete). Put a 160 and 60 in, runs like a CHAMP!! Forget the plug, listen to the other indicators and richen up your jetting. Happy Trails!