MOTORCYCLE SERVICE MANUAL

MODELS COVERED:

XR400R (1996-2004)

This Honda Motorcycle Manual is 352 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Serial numbers / Fasteners / Shop supplies / Basic tools / Precision measuring tools / Electrical system fundamentals / Special tools / Basic service methods / Storage

CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Starting the engine / Starting difficulties / Engine performance / Top end components / Preignition / Detonation / Engine noises / Engine leak down test / Fuel system / Test equipment / Ignition system / AC lighting system troubleshooting / Clutch / External shift mechanism and transmission / Kickstarter / Drive train noise / Front suspension and steering / Rear suspension / Frame noise / Brakes

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Service intervals / Torque specifications / Tune-up / Pre-ride inspection / Engine lubrication / Air filter / Spark plug / Engine compression check / Valve adjustment / Decompressor cable adjustment / Carburetor / Crankcase breather / Ignition timing / Control cable lubrication / Throttle cable adjustment / Clutch cable adjustment / Brakes / Drive chain and sprockets / Sidestand / Headlight aim / Tires and wheels / Wheel bearings / Steering / Front fork / Rear shock absorber / Rear swing arm and linkage / Spark arrestor cleaning / Nuts, bolts and other fasteners

CHAPTER FOUR / ENGINE TOP END
Engine operating principles / Exhaust system / Cylinder head cover / Camshaft and cam chain tensioner / Cylinder head / Valves and valve components / Cylinder / Piston and piston rings / Engine break-in

CHAPTER FIVE / ENGINE LOWER END
Engine / Cam chain, drive sprocket and tensioner guides / Crankcase and crankshaft / Engine break-in

CHAPTER SIX / CLUTCH AND EXTERNAL SHIFT MECHANISM
Clutch cover and clutch release arm / Right crankcase cover / Clutch / Oil pump drive gear and primary drive gear / Oil pump / Kickstarter and idle gear / External shift mechanism / Clutch cable replacement

CHAPTER SEVEN / TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission troubleshooting / Transmission / Transmission overhaul / Transmission inspection / Internal shift mechanism

CHAPTER EIGHT / FUEL AND EMISSION CONTROL SYSTEMS
Carburetor / Float level adjustment / Pilot screw adjustment / Carburetor rejetting / Fuel tank / Fuel shutoff valve / Throttle cable replacement / Air box / Emission control

CHAPTER NINE / ELECTRICAL SYSTEM
Component testing / AC lighting system testing / AC regulator / Left crankcase cover and stator coil / Flywheel / Ignition system testing / Ignition system component replacement / Ignition timing / Headlight / Taillight / Engine stop switch / Wiring diagram

CHAPTER TEN / WHEELS, TIRES AND DRIVE CHAIN
Front wheel / Rear wheel / Front and rear hubs / Wheel service / Tire changing / Drive chain / Sprocket replacement

CHAPTER ELEVEN / FRONT SUSPENSION AND STEERING
Handlebar / Steering head / Front fork / Front fork service / Front fork adjustment

CHAPTER TWELVE / REAR SUSPENSION
Rear suspension / Shock absorber / Shock linkage / Rear swing arm / Rear suspension adjustment

CHAPTER THIRTEEN / BRAKES
Brake fluid selection / Disc brake / Front brake replacement / Front brake caliper / Front master cylinder / Rear brake pad replacement / Rear brake caliper / Rear master cylinder / Brake hose replacement / Brake disc / Draining brake fluid / Brake bleeding / Rear brake pedal

CHAPTER FOURTEEN / OIL COOLER AND HOSES
Oil cooler / Oil cooler outlet hose / Oil pump outlet hose / Oil pump inlet hose

CHAPTER FIFTEEN / BODY
Seat / Side covers / Front visor / Front fender / Rear fender / Engine guard / Right side footpeg / Sidestand / Subframe / Odometer

WIRING DIAGRAM