1982 Honda XL400R, XL500R service manual

Table of Contents

1. GENERAL INFORMATION

• Introduction
• Model Identification
• General Specifications
• Maintenance Precautions
• Safety Information

2. MAINTENANCE

• Maintenance Schedule
• Lubrication Points
• Inspection Procedures

3. ENGINE

• Engine Removal and Installation
• Cylinder Head/Valve Train
• Cylinder and Piston
• Clutch
• Gearshift Linkage
• Crankcase and Crankshaft
• Engine Lubrication System
• Engine Cooling System

4. FUEL SYSTEM

• Fuel System Overview
• Carburetor
• Fuel Pump
• Fuel Tank and Lines

5. ELECTRICAL SYSTEM

• Electrical System Overview
• Wiring Diagrams
• Battery and Charging System
• Ignition System
• Starter Motor
• Lighting System
• Switches and Controls

6. DRIVE CHAIN

• Drive Chain Adjustment
• Drive Sprocket
• Chain Guide and Slider
• Chain Inspection and Replacement

7. BRAKES

• Front Brake
• Rear Brake
• Brake Adjustment
• Brake Lever Play
• Brake Inspection and Replacement

8. SUSPENSION

• Front Suspension
• Rear Suspension
• Fork Adjustment
• Shock Absorber Adjustment

9. STEERING

• Steering System Overview
• Steering Head Bearings
• Handlebar Adjustment

10. BODY

• Body Panels
• Seat
• Fender
• Side Covers

11. TROUBLESHOOTING

• Engine Troubleshooting
• Electrical Troubleshooting
• Fuel System Troubleshooting
• Drive Chain Troubleshooting
• Brake Troubleshooting
• Suspension Troubleshooting

12. SERVICE DATA AND SPECIFICATIONS

• General Specifications
• Torque Specifications
• Fluid Specifications
• Service Tools

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