Honda XR 400 Installation Manual
1. Get a degree in Mechanical and Electrical Engineering
2. Remove the seat, side panels, and gas tank
3. Unplug the green and blue taillight wires from the stock wiring harness, remove the taillight lens, and remove the taillight socket and wiring.
4. Unplug the headlight from the stock wiring harness and remove.
5. Remove the kill switch. Unplug the black/white wire and the black wire from the connector near the base of the odometer.
6. Locate the AC voltage regulator found mounted just above the engine and below the frame tube as shown in Photo 1. Unplug the regulator from the wiring harness and remove regulator. Note that the AC regulator has a locking detent tab that you have to pull out slightly for the connector to separate.
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.
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.
11. Brake Light Switch Installation: The latest XR 400 kit uses a hydraulic brake switch.
17. Rear Wiring Connections: You will now make all the connections required to the wiring harness at the rear of the bike