• MOTORCYCLE SERVICE MANUAL

MOTORCYCLE SERVICE MANUAL

MOTORCYCLE SERVICE MANUAL

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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

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Product Specifications

General Information

Brandclymer
Label@CLYMER HONDA XR400R 1996-2004
Universemoto
Categorymanuel_d_entretien
Supplier Part #CM3202
ITL ID252-M3202

Dimensions & Physical

Weight 0 lbs
Length0
Width0
Thickness0

Vehicle Fitment

Total Applications9
Applications HONDA XR400R 1996HONDA XR400R 1997HONDA XR400R 1998HONDA XR400R 1999HONDA XR400R 2000HONDA XR400R 2001HONDA XR400R 2002HONDA XR400R 2003HONDA XR400R 2004
Makes HONDA
Models XR400R
Years 199619971998199920002001200220032004

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