The Cyclepedia Press LLC Honda XR400R online service manual features detailed full-color photographs and color wiring diagrams, complete specifications with step-by-step procedures performed and written by a veteran Honda dealer trained motorcycle technician.

This manual covers 1996 – 2004 Honda XR400R motorcycles.

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Quick Reference
Specifications
General Torque Specifications
Torque Specifications
VIN and Engine Number Location

Periodic Maintenance
Air Filter Servicing
Brake Bleeding
Clutch Cable Adjustment
Compression Check
Drive Chain Adjustment
Engine Idle Speed
Engine Oil
Front Brake Inspection and Pad Replacement
Periodic Maintenance Chart
Rear Brake Pad Inspection & Replacement
Spark Arrester
Spark Plug
Throttle Free Play
Tires
Valve Adjustment
Wheel and Axle Inspection
Steering Inspection
Decompressor Service
Brake Pedal Adjustment

External Components
Exhaust System
Footpegs
Front Fender
Front Number Plate & Headlight
Fuel Tank
Rear Fender
Seat
Side Covers
Handlebar
Engine Guard
Side Stand
Gearshift Pedal
Subframe Removal & Installation
Kickstart Lever

Fuel System
Airbox
Carburetor Removal and Installation
Carburetor Assembly
Carburetor Disassembly
Petcock and Fuel Strainer

Engine
Camshaft Installation
Camshaft Removal
Clutch
Crankshaft
Crankcase Assembly
Crankcase Splitting
Cylinder Head
Cylinder and Piston
Engine Removal
Engine Installation
Left Side Engine Components Removal
Oil Pump
Gear Shift Linkage
Transmission Assembly
Transmission Removal
Valves
Left Side Engine Components Install
Oil Pipe Removal & Installation
Right Crankcase Cover
Cylinder Head Cover
Clutch Cover Removal & Installation
Crankcase Bearings
Kickstarter Assembly
Decompressor Assembly Removal
Right Hand Side Engine Components

Final Drive
Drive Chain
Engine Sprocket
Rear Sprocket

Steering
Steering Bearing Service

Front Suspension
Fork Removal and Installation
Front Suspension Adjustment
Front Fork Assembly
Front Fork Disassembly

Rear Suspension
Suspension Linkage
Shock Absorber Service
Swingarm
Shock Absorber Removal & Installation
Swingarm Bearing Inspection & Replacement
Rear Suspension Adjustment

Brakes
Front Caliper
Rear Brake Caliper
Master Cylinder
Rear Brake Master Cylinder
Brake Discs

Wheels
Wheel Bearing Replacement
Front Wheel
Rear Wheel

Electrical Systems
Lighting System
Ignition System & Troubleshooting
Stop Switch
Wiring Diagram
Headlight Bulb Replacement
Tail Light Bulb Replacement

Online Honda Parts Diagram Link

Honda XR400R Troubleshooting

Professional Tech Support