Edelbrock Automobile Parts XR400 User Manual

INSTRUCTION SUPPLEMENT FOR  
1996 and Later Honda XR400 &  
1988 and Later Honda XR600  
Removing stock carburetor and cables.  
1. Remove seat and gas tank. Make sure fuel  
petcock is in “off” position.  
2. Remove throttle cables paying close  
attention to routing, as the new cables will  
need too be routed the same.  
3. Remove stock carburetor and stock throttle  
housing.  
Figure 1.  
11. Align carburetor as close to vertical as  
possible and tighten manifold clamp.  
12. Adjust cable until wide-open throttle is  
achieved. Adjust return cable to take up the  
slack. Note: When throttle cables are  
properly adjusted, there should be  
4. Stuff a dry, clean rag into the intake  
manifold to keep debris from entering  
engine.  
approx. 1/8” of free play in the throttle.  
NOTE: It may be easier to remove sub-frame  
prior to installation. (XR400 only)  
13. After throttle cables have been adjusted the  
handle bars should be rotated from full right  
stop to full left stop while opening and  
closing throttle to ensure smooth operation.  
Also check to make sure the cables do not  
catch or bind on anything, i.e., hand guards,  
stabilizers.  
Installing the Edelbrock Carburetor and  
Throttle Cables  
5. Install the throttle cables into the supplied  
throttle housing and place onto clean  
handlebar end.  
6. Remove the rubber carburetor alignment  
tabs from the manifold using a razor blade or  
sharp cutters. This should be done with the  
rag left in the manifold. Be very careful not  
to damage the manifold or your hands  
while doing this!!  
14. Secure clamp around air boot onto back of  
carburetor.  
15. Install Remote Idle Cable into threaded tab  
on top of carburetor. Refer to main  
instruction manual for remote idle cable  
installation and adjustment.  
7. Remove the hex pipe plug from the carb cap  
using an 11mm or 7/16 wrench. Do not  
discard plug, as it will be needed later.  
Install the metering adjustment tool included  
in the hardware kit. Do not over-tighten as  
damage may occur to cap.  
16. Install fuel tank and connect fuel line to  
petcock and secure with provided pinch  
clamp. Refer to figure 1. Do not bolt tank in  
place, as minor adjustments may be  
necessary.  
8. Remove rag from manifold.  
17. Turn fuel petcock to on and check for  
leaks.  
9. Install carburetor into manifold. Do not  
tighten yet.  
18. Open throttle 3-5 times to prime accelerator  
pump. Do not open throttle any more than  
5 times as this may flood engine!!  
10. Install the pull cable (long shoulder on cable)  
into the 4:00 position and the return cable  
end into the 1:00 position of the cable  
wheel. Secure cables to cable bracket by  
replacing end piece and Phillips screw. See  
figure 1.  
19. Once pump is primed, get motor to TDC and  
kick through without opening throttle. If  
 

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