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Clymer Manual for XR400 96-04
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Clymer Manual for XR400 96-04

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    Product ID: #1010740



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    Product Information

    Clymer Manual for XR400 96-04

    MODELS COVERED:
    1996-2004 HONDA XR400R

    CONTENTS:

    CHAPTER ONE / GENERAL INFORMATION

    CHAPTER TWO / TROUBLESHOOTING

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

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

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

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

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

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

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

    WIRING DIAGRAM

    • Product ID: 1010740
    • Manufacturer:
      Clymer (learn more)
    • Manufacturer Part#: M320-2
    • Sold As: EA
    • Fits (click your bike to view all items for it):
      • Honda XR400R 1996
      • Honda XR400R 1997
      • Honda XR400R 1998
      • Honda XR400R 1999
      • Honda XR400R 2000
      • Honda XR400R 2001
      • Honda XR400R 2002
      • Honda XR400R 2003
      • Honda XR400R 2004
    • Condition: New, unless otherwise noted.
    • SoloMotoParts.com is an authorized Clymer dealer

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