Honda XR400R Motorcycle (1996-2004) Service Repair Manual

The online edition of this manual will be available immediately without download. The physical manual will be dispatched directly by Haynes and will arrive separately from any other parts ordered.

Clymer motorcycle repair manuals are written specifically for the do-it-yourself enthusiast. From basic maintenance to troubleshooting to complete overhaul, Clymer manuals provide the information you need. The most important tool in your tool box may be your Clymer manual, get one today.Every Clymer manual contains hundreds of original photographs and illustrations developed from a complete disassembly and assembly of a motorcycle. This, in addition to extensive research, allows Clymer to achieve an unmatched level of detail, accuracy and clarity.The step-by-step instructions and two-column text with large print are user-friendly. Bold figure numbers make it easy to quickly match instructions with illustrations and photos. Thumb-tabbed chapters, numbered table of contents and an extensive index make it possible to locate the desired section quickly.

The Haynes Online Manual gives you the trusted content of the famous printed Workshop Manual with extra features to get the job done. Online Manuals provide the following benefits: Troubleshooting tool for fast diagnosis of common problems. Colour-coded wiring diagrams for key systems. Videos tutorials for common DIY tasks. Colour photographs with approximately 750 in each manual. Photos can be zoomed in to observe key details. Fully searchable Dictionary of automotive terms. Hyperlinks to additional relevant information in other manual chapters. Print any page at home.

Honda XR400R manual.

What's Covered

THIS HONDA MOTORCYCLE MANUAL IS 352 PAGES.

• QUICK REFERENCE DATA
• CHAPTER ONE / GENERAL INFORMATIONMANUAL 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 / TROUBLESHOOTINGOPERATING 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-UPSERVICE 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 ENDENGINE 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 ENDENGINE / CAM CHAIN, DRIVE SPROCKET AND TENSIONER GUIDES / CRANKCASE AND CRANKSHAFT / ENGINE BREAK-IN
• CHAPTER SIX / CLUTCH AND EXTERNAL SHIFT MECHANISMCLUTCH 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 MECHANISMTRANSMISSION TROUBLESHOOTING / TRANSMISSION / TRANSMISSION OVERHAUL / TRANSMISSION INSPECTION / INTERNAL SHIFT MECHANISM
• CHAPTER EIGHT / FUEL AND EMISSION CONTROL SYSTEMSCARBURETOR / FLOAT LEVEL ADJUSTMENT / PILOT SCREW ADJUSTMENT / CARBURETOR REJETTING / FUEL TANK / FUEL SHUTOFF VALVE / THROTTLE CABLE REPLACEMENT / AIR BOX / EMISSION CONTROL
• CHAPTER NINE / ELECTRICAL SYSTEMCOMPONENT 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 CHAINFRONT WHEEL / REAR WHEEL / FRONT AND REAR HUBS / WHEEL SERVICE / TIRE CHANGING / DRIVE CHAIN / SPROCKET REPLACEMENT
• CHAPTER ELEVEN / FRONT SUSPENSION AND STEERINGHANDLEBAR / STEERING HEAD / FRONT FORK / FRONT FORK SERVICE / FRONT FORK ADJUSTMENT
• CHAPTER TWELVE / REAR SUSPENSIONREAR SUSPENSION / SHOCK ABSORBER / SHOCK LINKAGE / REAR SWING ARM / REAR SUSPENSION ADJUSTMENT
• CHAPTER THIRTEEN / BRAKESBRAKE 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 HOSESOIL COOLER / OIL COOLER OUTLET HOSE / OIL PUMP OUTLET HOSE / OIL PUMP INLET HOSE
• CHAPTER FIFTEEN / BODYSEAT / 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
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