Honda XR400R Service Manual – PDF DOWNLOAD

Description

Honda XR400R Service Manual – PDF DOWNLOAD

DESCRIPTION:

Honda XR400R Service Manual – PDF DOWNLOAD

HOW TO USE THIS MANUAL

• Follow the Maintenance Schedule (Section 3) recommendations to ensure that the vehicle is in peak operating condition and the emission levels are within the standards set by the California Air Resources Board. Performing the first led maintenance is very important.
• It compensates for the l wear that occurs during the break-in period. Sections 1 and 3 apply to the whole moto . Section 2 i procedures for removal/ installation of components that may be required to perform service described in the following sections. Section 4 through 16 describe parts of the motorcycle, grouped according to location.
• Find the sect ion you want on this page, then turn to the table of contents on the first page of that section. Most sections start with an assembly or system il lustration, service information and troubleshooting for the section. The subsequent pages give detailed procedures. If you don’t know the source of the trouble, go to section 18 Troubleshooting.
• ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO., LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER.
• NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON HONDA MOTORCYCLES, MOTOR SCOOTERS OR ATVS

IMPORTANT SAFETY NOTICE

WARNING

Indicates a strong possibility of severe personal injury or death if instructions are not followed.

CAUTION:

Indicates a possibility of equipment damage if instructions are not followed.

NOTE:

Gives helpful information.

Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. It is important to note that this manual contains some warnings and cautions against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand that those warnings could not cover all conceivable ways in which service, whether or not recommended by Honda might be done or of the possible hazardous consequences of each conceivable way, nor could Honda investigate all such ways. Anyone using service procedures or tools, whether or not recommended by Honda must satisfy himself thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service method or tools selected.

SERVICE RULES

1. Use genuine HONDA or HONDA-ended parts and lubricants or their equivalents. Parts that do not meet HONDA’s design specifications may damage the motorcycle.

2. Use the special tools designed for this product.

3. Use only metric tools when servicing this motorcycle. Metric bolts, nuts, and screws are not interchangeable wit h English fasteners. The use of incorrect tools and fasteners may damage the motorcycle.

4. Install new gaskets, O-rings, cotter pins, lock plates, etc. when reassembling.

5. When tightening a series of bolts or nuts, begin with the larger-diameter of inner bolts first, and tighten to the specified torque diagonally, in incremental steps unless a particular sequence is specified.

6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.

7. After assembly, check all parts for proper installa tion and operation.

8. Route all electrical w ires as show on pages 1-19 through 1-24, Cable and Harness Routing.
TABLE OF CONTENTS:

Honda XR400R Service Manual – PDF DOWNLOAD

Cover................................................  1
Contents.............................................  2
Symbols..............................................  4
1. General Information...............................  5
	Model Identification.............................  7
	Specifications...................................  8
	Torque Values.................................... 16
	Tools............................................ 19
	Lubrication & Seal Points........................ 21
	Cable & Harness Routing.......................... 23
	Emission Control Systems......................... 29
2. Frame/Body Panels/Exhaust System.................. 31
	Seat/Fuel Tank................................... 32
	Side Covers/Sub-Frame............................ 33
	Front Visor/Front Fender......................... 34
	Rear Fender/Under Guard.......................... 35
	Exhaust System................................... 36
3. Maintenance....................................... 37
	Fuel Line/Throttle Operation..................... 42
	Air Cleaner...................................... 43
	Crankcase Breather............................... 44
	Spark Plug....................................... 45
	Valve Clearance.................................. 46
	Engine Oil....................................... 47
	Engine Oil Filter................................ 49
	Decompressor System.............................. 50
	Engine Idle Speed/Drive Chain.................... 51
	Drive Chain Slider/Brake Fluid................... 54
	Rear Brake/Brake System.......................... 55
	Headlight Aim/Clutch System...................... 56
	Side Stand....................................... 57
	Suspension....................................... 58
	Spark Arrestor/Nuts, Bolts, Fasteners............ 59
	Wheels/Tires/Steering Head Bearings.............. 60
4. Lubrication System................................ 61
	Oil Pump & Strainer.............................. 63
	Oil Cooler & Oil Pipe............................ 67
5. Fuel System....................................... 70
	Specifications................................... 72
	Carburetor Removal............................... 73
	Carburetor Assembly.............................. 77
	Carburetor Installation.......................... 80
	Pilot Screw Adjustment........................... 81
	Carburetor Tuning ('96 - '97).................... 83
	Temperature & Altitude Adjustment (After '97).... 85
	Air Cleaner Housing.............................. 86
6. Engine Removal/Installation....................... 87
	Service Information.............................. 88
	Engine Removal................................... 89
	Engine Installation.............................. 91
7. Cylinder Head/Valve............................... 92
	Specifications................................... 93
	Troubleshooting.................................. 95
	Cylinder Compression............................. 96
	Cylinder Head Cover Removal...................... 97
	Camshaft Removal................................. 98
	Decompressor System..............................100
	Cylinder Head Cover Disassembly..................101
	Cylinder Head Removal............................102
	Cylinder Head Disassembly........................103
	Valve Guide Replacement..........................106
	Valve Seat Inspection/Refacing...................107
	Cylinder Head Assembly...........................110
	Cylinder Head Installation.......................111
	Camshaft Installation............................112
	Cam Shaft Tensioner Lifter Installation..........114
	Cylinder Head Cover Assembly.....................115
	Cylinder Head Cover Installation.................117
8. Cylinder/Piston...................................120
	Specifications...................................121
	Troubleshooting..................................122
	Cylinder Removal.................................123
	Piston Removal...................................124
	Piston/Piston Ring Installation..................127
	Cylinder Installation............................128
9. Clutch/Kickstarter/Gearshift Linkage..............129
	Specifications...................................130
	Troubleshooting..................................131
	Clutch Removal...................................132
	Clutch Installation..............................136
	Right Crankcase Cover............................140
	Primary Drive Gear...............................142
	Kickstarter......................................143
	Gearshift Linkage................................147
10. Alternator.......................................149
	Service Information..............................150
	Alternator Removal...............................151
	Alternator Installation..........................152
11. Transmission.....................................154
	Specifications...................................155
	Troubleshooting..................................156
	Crankcase Separation.............................157
	Transmission Disassembly.........................158
	Transmission Assembly............................163
	Crankcase Assembly...............................166
12. Crankshaft/Balancer..............................168
	Specifications/Troubleshooting...................169
	Crankshaft Removal...............................170
	Crankshaft Installation..........................173
13. Front Wheel/Suspension/Steering..................174
	Specifications...................................175
	Troubleshooting..................................176
	Front Wheel......................................177
	Fork.............................................183
	Handlebar........................................194
	Steering Stem....................................198
14. Rear Wheel/Suspension............................202
	Specifications...................................203
	Troubleshooting..................................205
	Rear Wheel.......................................206
	Shock Absorber...................................212
	Shock Linkage....................................229
	Swingarm.........................................233
15. Hydraulic Disc Brake.............................237
	Specifications...................................239
	Troubleshooting..................................240
	Brake Fluid Replacement/Air Bleeding.............241
	Brake Pad/Disc...................................243
	Front Master Cylinder............................244
	Front Caliper....................................246
	Rear Master Cylinder.............................249
	Rear Caliper.....................................252
	Brake Pedal......................................255
16. Electrical System................................257
	Specifications...................................258
	Troubleshooting..................................260
	Lighting System Inspection.......................262
	Ignition System Inspection.......................263
	Exciter Peak Voltage.............................264
	Ignition Pulse Generator Coil Peak Voltage.......265
	Ignition Timing..................................266
	Headlight/Taillight..............................267
	Engine Stop Switch...............................268
17. Wiring Diagram...................................269
18. Troubleshooting..................................270
19. Index............................................274

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