4Strokes.com Honda Technical: How to fit a CRF450R/X clutch perch to an XR400R By Brad Poulter

4Strokes.com - Dirt Bikes, ATVs & Dual Sport Motorcycles

This mod was done to get rid of the decompression lever on the handlebar of my 1997 Honda XR400R, as I wanted to make room for some smaller mirrors that mount with a hose clamp right where the lever was. As a bonus of using the CRF bits, I also benefit from a quick clutch adjuster and a span adjustable lever. Brad used genuine Honda parts available at most any Honda dealer. The complete list of parts is as follows:

Part Description	Part Number	Qty
Bracket left handle lever	53172MEN670	1
Cap left lever mount	53174KCE670	1
Cover left handle lever	53177MEN670	1
Lever left starting handle	53178MEN670	1
Dial clutch cable	53179MEN671	1
Lever hot start	53190MEN670	1
Bolt wire adjust	53192MEN670	1
Bolt, handle lever P	90113MEN670	1
Socket Bolt, Adjust L	90118MEN670	1
Collar, Pivot	90501MEN670	1
Nut hex 6mm	94001062000S	2
Bolt, flange 6X22	960010602200	2

Complete clutch assembly preassembled prior to install.

Motor end of cables. CRF450R/X hot start cable on top and XR400R decompression cable on bottom.

Unfortunately the standard decompression cable was too short, as I had put higher-rise bars on my bike and the lever is now on the top. No amount of rerouting sorted the length issue. A trip to the Honda dealer later and I had a CRF450R/X hot start cable. This gave me approximately 3" more length. However the cable ends and adjusters were different. See photos above.

Lever end of cables. CRF450R/X hot start cable on top and XR400R decompression cable on bottom.

Finished! Everything is neat and tidy.

I chopped the lever end off the old cable and fitted it to the new one. This required drilling out the XR cable adjuster to fit the end of the CRF cable. Also the sheath on the CRF cable on the lever end has to have about ½" removed to get the free play adjustment correct. The CRF cable end will not fit into the XR lever so you will need to use the XR one. Get the old end of the XR cable that you cut off before and drill it to get rid of the old bit of cable and then one side of the hole has to be enlarged to fit the end of the CRF cable. Then use a hacksaw to cut down the side of the cable end so it can fit into the end. Then you can solder it closed and have a strong cable end.

I'm very happy with the result as now I have a smaller reach to the clutch lever (I have small hands) and I only have to move the clutch lever a very short distance for racing changes. (I race Supermotard and do track days)

Alternative to cable modification: If you don't care to modify your cables as described above, you can have custom cables made at most any larger motorcycle shop.

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