HARD to START 2002 Honda XR 400R CARBURETOR HOW TO remove clean rebuild upgrade dirtbike JETTING FIX

Very HARD to START dirtbike 2002 Honda XR 400R CARBURETOR HOW TO remove clean rebuild UPGRADE modify replace JETS proper jetting ( what size jets ) to increase performance ( Gordon's Mods ) and make it MUCH EASIER STARTING Common problem same procedure on many years makes and models main jet pilot slow jet float needle valve float adjustment remove snorkel
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PLEASE KEEP IN MIND when you are watching my videos: I am showing you the least expensive, quickest "backyard" methods for repairing or servicing your lawnmower or equipment. Replacing all components such as gaskets and fuel lines is always recommended when rebuilding or repairing equipment. With these videos I hope you are able to fix and repair your lawnmower pressure washer generator or motorcycle yourself with minimal parts, knowledge and tools. Thank you for watching!
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[@HaywardFamilybuilding]

Believe it or not you can take the carb out with out removing the sub frame or anything else. The trick is to remove the bolts on the rubber part between the carb and the engine. Then the carb will come out

[@JeffsLittleEngineService]

Thanks friend, I will try that way next time

[@davidcox692]

I bought one of these in 1999 brand new and always had a problem starting it, ended up selling it with only 600 miles on, shame I didn't see your video then lol

[@jeffrichards8054]

Thanks! This was just what I needed to motivate me to clean up my '04 xr400 carb. I didn't re-jet, just cleaned many years of varnish and crud out of entire carb and plugged jets. My formerly hard to start wonder bike started after 5 prime kicks and one start kick! Running great again!

[@JeffsLittleEngineService]

The larger jets really helped me out with the hard starting too

[@solarwindnomad3083]

Congrats, that XR is starting easy, or your skill is expert level. Mine only starts with starter spray for now, I changed already Fuel Tank switch which was very clogged. Now I'm dismanteling Carb.... Thanks for your instruction video !

[@JeffsLittleEngineService]

make sure pilot jet is clean! that is usually the problem

[@gti20vtMarcel]

Hi Jeff, the screw in the front is for the air adjustment and the diaphragm is the air cut-off valve, further you're missing the plastic splash guard (against fuel surge in rough terain) that goes around the main jet, clear vid! 👍

[@JeffsLittleEngineService]

Excellent info friend Thank you! I did not what the small diaphragm was for.

[@frankiemarchese2978]

The screw in the front is actually a fuel adjustment, not air. Air screws are located on the intake side of the carb, fuel screws are on the engine side

[@gti20vtMarcel]

@@frankiemarchese2978 Not on a XR carb, to be exact i was talking about the Air/Fuel idle mixture srew! Calling it only a air screw you are right but most people understand what was meant. 😉

[@frankiemarchese2978]

@@gti20vtMarcel I understand what you meant 👍 but it is a fuel mixture screw, it only meters the amount of fuel going through. For example, an xr80r has an air mixture screw on the back of the carb because it meters the air going through. Most 2 strokes have an air mixture screw too. Its never both a fuel/air mixture screw, its one or the other. My xr100r and 400r has a fuel screw ⛽️

[@gti20vtMarcel]

@@frankiemarchese2978 Okay, and turning the screw in means leaner allthough in a 2 stroke turning in the Air screw in is for a richer mixture. ✌️

[@kiddhartwell1312]

You're a scholar and a gentleman good sir!, thank you for this vid!

[@JeffsLittleEngineService]

Glad it was helpful! Thanks friend

[@tkinson]

Gorgeous dog!

[@JeffsLittleEngineService]

Thanks for watching everyone!

[@Philisnotretired]

My carb has a plastic piece that fits on the main jet - an anti-cavitation, anti-splash thingy. I noticed you don’t have one. Is it unnecessary?

[@JeffsLittleEngineService]

Good question. I ride my bike hard offroad, on the street and on a track sometimes and it has always ran perfect since I rejetted it. I usually trust Honda/Mikuni engineers but I would say due to experience it is not necessary.

[@robertmailhos8159]

Running like a top now 👍

[@JeffsLittleEngineService]

It was ridiculously hard to start and was running waaay too lean apparently. Thanks for watching Robert and thanks for commenting

[@robertmailhos8159]

@@JeffsLittleEngineService you are welcome young man 👍😎

[@squirrelcam]

love the chooks!

[@StansE250]

Hey Jeff ! Thanks for the vid 👍🏼 Very Thorough, well-prepared presentation (no ummm, uhhs,). I’m moving to OR early November. Been ‘shopping’ for a ‘97-‘04 XR400R. Might get one in SoCal before, or wait. How hard is it to get (dirt) bikes plated there ? For Dual Sport use ….

[@JeffsLittleEngineService]

Hi friend! unfortunately Oregon does not allow dirtbikes to be plated. Washington does with appropriate modifications like turn signals, D.O.T. approved headlight and freeway speed rated tires. Some local motorcycle shops do the one time approval process/inspection and can help you make the right mods to get license plates.

[@StansE250]

@@JeffsLittleEngineService CRAAAAPP ! Thanks for the info 😩

[@SOLDOZER]

I had a 98 XR400 back in the day. It was a pain to start.

[@JeffsLittleEngineService]

Yes, it seems they are all hard to start unless the carb jets have been replaced

[@markr3140]

Job to do, thanks for sharing! Think mine is too lean, seems standard on these!! Cheers

[@JeffsLittleEngineService]

Yep I agree. Thanks for watching!

[@claytontycksen9472]

Great video, Jeff! I love how you got the camera angles up close so we can see what you're doing. Where did you order your jets and replacement float valve from?

[@JeffsLittleEngineService]

Needle valve was from a Honda dealer and the jet kit was either Amazon or Ebay

[@petebaumbach7944]

thank you for this .. really helped .. Pete from UK

[@JeffsLittleEngineService]

Glad it helped. I love my XR's!

[@michaelfernandez688]

LOVE the video! Thank you for posting it and doing a great job at explaining everything. I have owned my 2002 XR400 for 10 + years and I never did a carb clean or rebuilt. Went to start it up and it is now time as it leaks a lot. Any recommendations on what else to replace or add while I have the carb taken apart? Newbie here, trying to make sure I do everything now and don't forget to clean or add any used parts that may fail in the near future. Can you also drop a link or elaborate on where you bought your items from Ebay? There are so many choices

[@JeffsLittleEngineService]

If it is leaking it wiill need a new float needle. All Genuine Honda parts for the most part. I believe the jet kit was an Ebay purchase.

[@1176hambone]

clean carb, jet correctly, set float height, adjust valves.

[@FloridaDualSport]

Thx for a great video!

[@JeffsLittleEngineService]

I hope it helped! thanks for watching

[@mr1pearl]

This is how we due it la la la la la la la 🎶🎵 sorry just watched the masked singer 🤷 I got to do my Yamaha 125 and I've been putting it off for ever but now I'll just put it off some more 😆 Nooo I'll get it 👍

[@EstebanEliasAguirreMartinez]

Hi anyone knows where can i find nedle seat for xr 400 2002 ? It needs to be replaced , thanks

[@JeffsLittleEngineService]

From Honda or Ebay.

[@MAJ_TADean]

Seems like the long way to dismantle it. Wouldn’t taking the I take bolts out be easier and quicker?

[@jimellis1810]

That side cover with the spring/rubber looks like an air cutoff valve to prevent backfiring when you let off the throttle. They do go bad once in a while.

[@JeffsLittleEngineService]

Good info!

[@IsleOfADV]

I know the XR 250/ XR400 dies if you touch the throttle on cold starts and hard to start on cold starts, but all I wanna know is does the fuel efficiency change by a huge amount if you change the jet sizes ?

[@JeffsLittleEngineService]

Not real noticeable to me definitely worth the modification for ease of starting and more all around horsepower.

[@cellanimation]

I'm restoring (and replacing) a Chinese made XR400 copy. Eventually I'll replace all the mechanical parts with genuine Honda ones, til then I'm just switching the carburetor. It's incredibly hard to find information on the specific model (shineray XY400), but I see no reason that an original Honda carby won't fit and function on my Chonda engine. Any tips (other than avoiding chinese engines?)

[@cellanimation]

Maybe the size is deceptive, but I think the corner of a leather chamois polishing cloth could get into the brass seat and apply enough friction to clean it quickly without scratching

[@JeffsLittleEngineService]

Sorry all i can say is that I would strongly advise getting a Honda, or Kawasaki, Suzuki KTM or some other name brand bike. Numerous problems will occur in the future with the chinese made crap. Availability of parts will also be a problem.

[@Handelson]

Jeff, thank you for this video. Question: i just bought an '03 XR400, it starts fine and idles for a minute and then dies with a gasping sound. Does that sound like a carburetor issue?

[@JeffsLittleEngineService]

yes most likely

[@milkcam]

@@JeffsLittleEngineService My 2001 XR400 throttle gets stuck when riding and also dies on idle. It’s backfiring loud as well. Any ideas?

[@markr3140]

⁠@@milkcam carb needs a clean / service. Check the diaphragm isn’t split, as the back firing is normally caused by that but also sounds like the needle is sticking

[@jamesringler987]

That sounds like a restricted midrange jet or too lean

[@MrCleanEmpire]

Wait why did you replace the jets? I was looking at a 03 that's for sale but all that work to get the carb cleaned out makes me rethink my decision about buying it as my first bike, you think a 98 Yamaha WR400 would be a better option?

[@JeffsLittleEngineService]

I love the XR's 250's and 400's.. I am not familiar with riding a WR. Working on a WR would be somewhat similar to working on an XR I would guess.

[@kumaclimber]

How did you get those plated? I'm in Oregon and really really want to plate mine

[@JeffsLittleEngineService]

You can do it in Washington just need lights, brake switch stoplight and highway tires

[@FloridaDualSport]

I have a 2023 in Florida. Plated in south dakota. EZ

[@FloridaDualSport]

Sorry. Meant a 2003 xr400 plated in S. Dakota

[@benkanobe7500]

Where did you order your Jets and Niddle Valve from?

[@JeffsLittleEngineService]

I got them on Ebay

[@gertkristensen6451]

good job

[@JeffsLittleEngineService]

Thanks friend

[@michaelfernandez688]

Hey Jeff, any chance you can respond?

[@kylechupick2232]

Any clue how to fix the idle to full throttle bog? Besides raising the idle

[@JeffsLittleEngineService]

I would recommend as full carburetor cleaning and or rebuilding/adjusting the carb

[@rickyrickharris4908]

Ya that wasn't warmed up at all hahha

[@MartinTapperMedia]

Like because chicken intro

[@jjjuarez312]

Sounds like slack in the timing chain or vavles out of adjustment...

[@JeffsLittleEngineService]

I will check, thanks for the tip

[@santiagopenaloza9401]

💪💪🇯🇵

[@miker7808]

I bet it was a completely different day when you started it. Look at the sunshine and shadows and your clothes. Come on man be honest, you had to kick the crap out of it.