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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