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-   -   Lighting problem on XR400R (http://www.horizonsunlimited.com/hubb/honda-tech/lighting-problem-on-xr400r-50892)

going_somewhere 17 Jun 2010 09:41

Lighting problem on XR400R
Hi All

The headlight + Tail light (Not the brake light, though) on my XR keep blowing at the same time. Both stopped working entirely a few weeks ago when a connection came loose which, even for the likes of me, was obviously a piece of piss to fix. When putting the connectors back together i noticed that the clear plastic sleeve was burned black, as were the connections. Probably the reason why they came loose in the first place..

SO, my question.. Does anybody have any idea what could be causing this? A short somewhere, or dodgy voltage regulator? I'm not an electrician so have no idea!

Cheers for your help!


Mickey D 17 Jun 2010 09:57

Sounds like a bad Voltage reg, but cause could be bad battery.
Have someone check the output at the battery and at the VR. Several tests will sort this out.

You should fix it so you do not damage the Stator ... expensive part.

The VR is relatively cheap. Also replace any burnt or funky plugs or connectors. Use Dilectric grease on spade plugs and connectors.

Check battery. Make sure its good under load. Bad battery probably caused VR to fry. Will fry your stator next.

Good luck.

going_somewhere 17 Jun 2010 12:14

Thanks for the reply Mickey

XR400's don't have a battery, so i guess i should just get the regulator replaced straightaway.
Since it can't have been a dodgy battery, do you know what could have caused this?



Pigford 17 Jun 2010 21:54

Could even just be loose/dirt connections, including a bad earth (again loose or dirty connection).

Obviously dirt bikes suffer from an excess of wet & corroded bits, let alone knocks & bangs, so good idea to check ALL connectors are tight & clean :thumbup1:

Mickey D 17 Jun 2010 22:00

I thought perhaps you had a different version of the XR400. In the US XR400's did not come with batteries either, sounds like same version you have. I believe Honda sell "Street Legal" XR400's in some countries. These would be substantially different. Honda discontinued the XR400 in the USA in about 2002 or so. They make various versions in Brazil using similar motor.

My '98 XR400 had a Baja Designs kit on it. It did use a small Ni-Cad battery pack to allow lights, horn and signals to work with motor off. This is a legal requirement in USA. Excellent system, 100% reliable.

So you're running 100% off the Stator. Nearly sure to be bad Reg-Rectifier.
But have someone qualified check it out to make sure. Takes about 5 minutes to do the checks using a VOM. (volt-Ohm meter)

going_somewhere 25 Jun 2010 04:10

I've replaced both bulbs, and i've got another 600k or so to go until i get to the next bike mechanic, so i'll see what happens over the next day or so. I'm hoping Pigford's right and it's only the loose connection that caused the problem. If they both still work when i get into town, i'll take a chance and leave it as it is. I really can't afford anything other than oil at the moment.. :mchappy:

Thanks for the replys!


Dazzerrtw 25 Jun 2010 07:59

If It help's
I had one XR400 that used to do the same.

It took ages to solve.

After many blubs and head scratching it turned out to be the earth to the frame that was the fault.

Hope you get it sorted.


going_somewhere 25 Jun 2010 20:10

Hi dazzer

For lazyness's sake, whereabouts is the earth? i'll have a look at that in a bit.



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