Honda XR400 Manual

Honda XR400 Manual

Honda XR400 Manual: This manual is for the 1996 – 2004  XR400R Model Honda Motorcycle. It covers in detail the complete maintenance schedules, service details, and repair instructions.

The Honda XR400 Manuals have been specifically designed by Honda engineers for the do-it-yourself-er, geared towards the backyard mechanic and also the experienced professional.

Every Honda XR400 Manual contains hundreds of pages of original photographs and illustrations obtained direct off of the Honda Factory Service Line and will come complete with 100% dis-assembly and re-assembly of the Honda motorcycle.

This item is an absolute must buy for the home garage. Do yourself a huge favor and buy a copy now. This way you can learn how to take of your new motorcycle.

Honda XR400 Manual

This Honda XR400 Service Manual is 352 Pages:

CHAPTER ONE / XR400 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 / XR400 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 / XR400 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 / XR400 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 / XR400 ENGINE LOWER END
Engine / Cam chain, drive sprocket and tensioner guides / Crankcase and crankshaft / Engine break-in

CHAPTER SIX / XR400 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 / XR400 TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission troubleshooting / Transmission / Transmission overhaul / Transmission inspection / Internal shift mechanism

CHAPTER EIGHT / XR400 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 / XR400 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 / XR400 WHEELS, TIRES AND DRIVE CHAIN
Front wheel / Rear wheel / Front and rear hubs / Wheel service / Tire changing / Drive chain / Sprocket replacement

CHAPTER ELEVEN / XR400 FRONT SUSPENSION AND STEERING
Handlebar / Steering head / Front fork / Front fork service / Front fork adjustment

CHAPTER TWELVE / XR400 REAR SUSPENSION
Rear suspension / Shock absorber / Shock linkage / Rear swing arm / Rear suspension adjustment

CHAPTER THIRTEEN / XR400 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 / XR400 OIL COOLER AND HOSES
Oil cooler / Oil cooler outlet hose / Oil pump outlet hose / Oil pump inlet hose

CHAPTER FIFTEEN / XR400 BODY
Seat / Side covers / Front visor / Front fender / Rear fender / Engine guard / Right side footpeg / Sidestand / Subframe / Odometer

The Honda XR400 Manual Includes a Full Color WIRING DIAGRAM

Honda XR400 Service Manual Models covered:
1996 1997 1998 1999 2000 2001 2002 2002 2003 2004 XR400R XR 400R 400 R+

Please Share Our Content Around the Web