Honda XR400R Manual
This Clymer motorcycle manual covers the Honda XR400R for the years indicated below:
Models Included are:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2002, 2003, 2004 XR400R
GENERAL INFORMATION
TROUBLESHOOTING
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
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
ENGINE LOWER END
Engine / Cam chain, drive sprocket and tensioner guides / Crankcase and crankshaft / Engine break-in
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
TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission troubleshooting / Transmission / Transmission overhaul / Transmission inspection / Internal shift mechanism
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
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
WHEELS, TIRES AND DRIVE CHAIN
Front wheel / Rear wheel / Front and rear hubs / Wheel service / Tire changing / Drive chain / Sprocket replacement
FRONT SUSPENSION AND STEERING
Handlebar / Steering head / Front fork / Front fork service / Front fork adjustment
REAR SUSPENSION
Rear suspension / Shock absorber / Shock linkage / Rear swing arm / Rear suspension adjustment
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
OIL COOLER AND HOSES
Oil cooler / Oil cooler outlet hose / Oil pump outlet hose / Oil pump inlet hose
BODY
Seat / Side covers / Front visor / Front fender / Rear fender / Engine guard / Right side footpeg / Sidestand / Subframe / Odometer
WIRING DIAGRAM
Models covered:
1996 1997 1998 1999 2000 2001 2002 2002 2003 2004 XR400R XR 400R 400 R
International Shipping
