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Honda: Technical Information | Technical Tips | Links to Technical Information


- Non-model Specific -


Disc Exhaust Tuning

Disc Type Exhaust System Setup (PDF)

Intended for 85-87 & 91-98 XR600R and 93-98 XR650L with a WB E-series exhaust system. May be helpful for other disc systems too. -White Bros


Honda Exhaust Noise Test Data

Honda Exhaust Noise Test Data (PDF)

Exhaust dB levels for Honda dirt bikes with various aftermarket exhaust systems. Go to CA St Parks OHMV Rec Div Website for latest edition. -John Franger


DIY Ignition Switch

Keyed Ignition Switch Install (Forums)

Install a keyed ignition switch on a dirt bike that did not already have one. -b_king


Measurement of Honda Exhaust Sound Levels

Measurement of Honda Exhaust Sound Levels (PDF)

SAE Standard test procedure, environment and instruments for determining sound levels. -SAE


XR/XL Spring Rates per Rider's Weight

Spring Rate Per Rider Weight

Is your XR or XL fork and shock sprung correctly for your weight and riding style? It makes all the difference in the world!


- CRF450X -


CRF450X Electrical Wiring Diagram, 2005 Model Year (GIF)


- XR100R -


Cheap XR100R Mods

XR100R Cheap Mods

After reading 4Strokes.com, I decided to volunteer mods I did on my 6yr old son's '00 XR100R. Cost was about $10 just for carb jets. -Greg Kipp


- XR200 -


Stuart's XR200 Hop-Up's!

XR200 Mods by Stuart

I just bought a 1983 XR200 as a 2nd bike and did these mods to increase performance. -Stuart Watson


- XR200R -


XR200R 84-85 On CDI Testing Table

XR200R CDI Testing Table, 1984/1985 and On (GIF)

Submitted by Jared (Jayrod1318)


XR200R 84-85 CDI Wiring Color Code

XR200R CDI Wiring Color Codes, 1984/1985 and On

Submitted by Jared (Jayrod1318)


XR200R Front Fork Mod

XR200R Front Suspension Mods

Here is what I did to get the best performing dampening rod-type forks that I have ever had. -NOS


Installing Lights on the XR200R

XR200R Light Installation

Install an aftermarket headlight and taillight on the XR200R that did not come with lights. -4Strokes.com


Wally's XR200R Hop-Ups!

XR200R Mods by Wally King

The most impressive mod I did to my 1990 XR200R was adapting a Kawasaki KX front-end.

- XR400R Continued -


Carburetor Adjustments & Tuning

XR400R Carb Adjustments & Tuning (36mm Keihin)

As delivered, with exhaust baffle and noise suppressor, your XR400R may be jetted rich. -4Strokes.com


Fit a CRF450R/X clutch perch to an XR400R

XR400R Clutch Perch Mod

Adapt a CRF450 clutch with perch hot start lever to your XR400R. -Brad Poulter


Decompression System Adjustment

XR400R Decompression System Adjustment

Automatic decompression is interlocked with the XR400R cam to make starting easier. -4Strokes.com


XR400R Engine Oil Checking & Changing

XR400R Engine Oil Checking and Changing

How to check and how to change engine oil in the XR400R.


Pictures of XR400R Engine Work

XR400R Engine Work Photos

Pictures taken during the rebuild of an XR400R motor. -ThumperTDC


XR400R Muffler Comparison

XR400R Exhaust System Comparison

HP and Torque for stock and aftermarket XR400R exhausts. -Jack Jensen


XR400R Fork Valve-Stack Compression Mod

XR400R Fork Valve Stack Mod (Forums)

High speed compression, like when riding over rocks, was much improved. -Trailryder42


USD Fork on XR400R

XR400R Front End Mod to USD Forks

Complete inverted fork mod with Race Tech Gold Valves on an XR400R. -ThumperTDC


XR400R Front Number-Plate Mod

Cycra CRF450R half-vented front number-plate in place of stock XR400R headlight. -kountryboy


Gordon Mods (for the XR400R)

XR400R Gordon Mods

Carb jetting, exhaust baffle mod, header weld grind, intake uncork, etc. Must do mods for the Honda XR400R. -Gordon Banks


Gordon Mods (for the XR400R)

XR400R Hydraulic Clutch

Carb jetting, exhaust baffle mod, header weld grind, intake uncork, etc. Must do mods for the Honda XR400R. -Gordon Banks


Lever Pivot Bolt & Boot

XR400R Lever Pivot Bolt and Boot

Clean mod when replacing stock hand guards with bar-mount style. -4Strokes.com


XR400R Mods/Setup Database

XR400R Mod and Setup Info

Lots of modification and setup info for the 1996, 1997 and 1998 Honda XR400R.


Joe's XR400R Hop-Ups!

XR400R Mods by Joe S.

I have had my XR400R for nearly 4 years now and after all this time I'm still not ready to part with it.

- XR650L Continued -


XR650L Battery Relocation Mod by Ryan

I took off the entire battery, trashed the bracket, and built a different one.


XR650L Battery Relocation Mod by SpudRider (Forums)

XR650L battery and electrical relocation mod.


XR650L Carb Fuel Mixture Screw Mod

XR650L Carb Fuel Mixture Screw Mod

Build your own extended fuel mixture screw out of an inexpensive valve stem cap. -Brian Farewell


XR650L Carb Mods

Dave's Carb Mods

XR650L Keihin 42.5mm diaphragm CV carb mods by Dave Closs and Brian Jackson.


XR650L Chain Guide Mod

XR650L Chain Guide Mod by SpudRider (Forums)

Replacing the drive chain guide rub block with chain rollers.


Clarke 4.7 Gallon Gas Tank Stabilizer

XR650L Clarke 4.7-Gallon Gas Tank Stabilizer

Easy 30-minute mod and your Clarke gas tank will be rock solid. -Forum members


1993-2000 Honda XR650L Esthetic Changes

XR650L Esthetic Changes from 1993-2000

Esthetic changes through model years 1993-2000. -xr250rguy


XR600R & XR650L Exhaust Baffle Mod

XR650L Exhaust Baffle Mod

Replace the stock XR650L exhaust baffle with a larger baffle from the Honda ATC 250R. -kubiak


Factory XR400R Oil Cooler on XR650L

XR650L Oil Cooler Mod by Helrich

Factory XR400R frame oil cooler adapted to the XR650L.


XR650L Oil Cooler

XR650L Oil Cooler Mod by Rotorcraft

Aftermarket Lockhart oil cooler grafted into the XR650L air scoops.


Oil Drain Funnel

XR650L Oil Drain Funnel

Why pay $20.00 for a special "man" funnel when you can make one for less than $2.00? -KingTutt


CRF450 Fender on XR650L

XR650L Rear Fender Mod

Aftermarket Polisport CRF450 rear fender and taillight adapted to the XR650L. -Simapg


XR650L Smog Removal

XR650L Smog Removal

Complete XR650L smog removal procedure with photos. -Gary Crawford


XR650L Smog Removal and Block-Off Procedure

How to uncork and remove smog equipment ib a 2003 XR650L. -Kyle Swanson


XR650L Smog Block-Off w/Pics

XR650L Smog Removal & Block-Off Procedure (Forums)

Carb vacuum ports to block off when removing smog equipment from an XR650L. -Mike Tuttle



84 XR200R Wiring Diagram

XR200R Electrical Wiring Diagram for 1984 Model

Submitted by Jared (Jayrod1318)


- XR250L -


Modifying the XR250L

XR250L Mods

Have you noticed how heavy the XR250L is in stock trim or its lack of acceleration? -Rick Ramsey


XR250L Tips and Tricks

This article is based on the Australian model 1997 XR250L but may also be beneficial for other XRs. -Daniel Stebbeings


XR250L Wiring Diagram

XR250L Wiring Diagram, 1991-1996

Page 1 (GIF), Page 2 (GIF)

Submitted by Ian (marshman)


- XR250R -


XR250R 84-85 On CDI Testing Table

XR250R CDI Testing Table, 1984/1985 and On (GIF)

Submitted by Jared (Jayrod1318)


XR250R 84-85 CDI Wiring Color Code

XR250R CDI Wiring Color Codes, 1984-1985 and On (GIF)

Submitted by Jared (Jayrod1318)


XR250R Exhaust Mod

XR250R Exhaust Mod

Wedge a screwdriver in the hole in the end-cap where the screw was. -Stuart Moss


Make Your Own XR250R Lowering Link

XR250R Lowering Link, Make Your Own (Forums)

Complete dimensions to make your own XR250R lowering link. -Stu


XR250R 84 Wiring Diagram

XR250R Wiring Diagram, 1984 Model (GIF)

Submitted by Jared (Jayrod1318)


96-99 XR250R Wiring Diagram

XR250R Wiring Diagram, 1996-1999 (GIF)

Submitted by Brian Sutherland


- XR350R -


85 XR350R Wiring Diagram

XR350R Wiring Diagram, 1985 Model

Submitted by Chris/Catuk


- XR400R -


XR400R Airbox Mod

XR400R Airbox Mod

I noticed a much crisper throttle response and the engine seemed to rev faster than before. -ThumperTDC


Intake Air-Box Snorkel Removal

XR400R Intake Airbox Snorkel Removal

Uncork your XR400R by yanking the airbox snorkel/baffle for newfound power! -4Strokes.com


XR400R Brake Light

XR400R Brake Light

Add an aftermarket brake light to your XR400R. Two submissions.

XR400R Passenger Pegs

XR400R Passenger Foot Pegs

Adapting XR650L passenger foot pegs to the XR400R. -Robb N


XR400R Speed vs RPM Calculator (XLS)

Calculate speed vs RPM for various tire and sprocket sizes. -Bob Bendt


Honda XR400R Stator Upgrade by Robb (b_king)

XR400R Stator Upgrade

200W stator upgrade to power dual headlights and other accessories. -Robb Nelsen


XR400R Wiring Diagram

XR400R Wiring Diagram, 1996-2004 (GIF)

XR400R electrical and wiring diagram or schematic.


- XR500R -


XR500R Replacement CDI

XR500R Replacement CDI

Rewire a 93-00 XR600R CDI to use in a mid-80s XR500R. -Greasser


- XL600R -


CRF450 Fender on XR650L

XL600R Chain Slider (Forums)

Jeb's answer to a hard-to-find XL600R lower chain slider. Build your own! -Jeb Massie


Add a Cooling Fan to Your XR650R

XL600R Oil Cooler and Fan (Gallery)

Gallery photo of oil cooler and computer fan on an XL600R. -Earl


- XR600R -


XR600R Dual Sport Project Bike

XR600R Dual-Sport Project

I have wanted to build a custom dual sport XR600R. -Tom Niemela


XR600R & XR650L Exhaust Baffle Mod

XR600R Exhaust Baffle Mod

Replace the stock XR600R or XR650L exhaust baffle with a larger ATC 250R baffle. -kubiak


10 Tips for the XR600R from Scott Summers

XR600R Upgrades and Tips

Scott Summers and Fred Bramblett's tips to make the XR600R more competitive and reliable for off-road desert racing.


Setting Valve Clearances on the XR600R

XR600R Valve Clearance / Lash Adjustment

How to adjust the valve clearances or lash on the Honda XR600R. -Craig Cullen


XR600R 88-90 Wiring Diagram

XR600R Wiring Diagram / Schematic, 1988-1990 (GIF)


XR600R 91-93 Wiring Diagram

XR600R Wiring Diagram / Schematic, 1991-1993 (GIF)


- XR650L -


XR650L Battery Relocation

XR650L Battery Relocation Mod by cracked junior

XR650L battery and electrical relocation mod.

XR650L non-CA model Smog Removal

XR650L Smog Removal, Non-California Model (Forums)

Smog removal on a non-CA model XR650L. -ALS650L


XR650L Windshield

XR650L Windshield

$25 online auction Kawasaki KLR smoked windshield grafted to an XR650L headlight bezel. -Jlutty650L


XR650L 93 Wiring Diagram

XR650L Wiring Diagram, 1993 (GIF)

Submitted by Tim Hixson


93-95 XR650L Wiring Diagram

XR650L Wiring Diagram, 1993-1995 (GIF)

Submitted by Tim Hixson


XR650L Simplified Schematic for Safeties

XR650L Wiring Safeties (GIF)

Electrical points that affect XR650L engine operation. -Dave Closs


- XR600R -


XR650R Air-Box Mod

XR650R Airbox Mod

Popular airbox mod for the XR650R, cut different shape holes and back with screen. -qadsan


Add a Cooling Fan to Your XR650R

XR650R Cooling Fan Mod

Complete procedure showing how to add a computer style fan to your XR650R. -Andy Waddell


XR650R Race Prep Tips

XR650R Race Prep Tips

Check right foot peg bolts; be sure front lower clip on air filter has good tension; etc. -guest


XR650R Side Panel Grab Hole

XR650R Side Panel Grab Hole

The right side panel has an area that can be cut open to access the subframe for lifting. -4StroKen


XR650R Stator Rewind

XR650R Stator Rewind

You installed a mega-watt headlight only to find seriously lacking power from your XR650R stator. -Eric Foster


Uncorking the Honda XR650R BRP By Bob Naumann

XR650R Uncork by Bob

This is the procedure Bob used to uncork his 2000 XR650R Big Red Pig for better performance and to pull a wheelie easier! -Bob Naumann


Uncorking the Honda XR650R

XR650R Uncork Per Factory Honda Tech Bulletin

Uncork the XR650R for better performance using all factory parts per Honda.


XR650R Electrical Wiring Diagram

XR650R Wiring Diagram (GIF)

Complete wiring diagram or schematic for the Honda XR650R.


Honda: Technical Information | Technical Tips | Links to Technical Information
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