1996-2004 Honda XR400R Service Manual

Shop manual for the Honda XR400R with detailed procedures for component removal/installation and system troubleshooting. Ref: 61CT000

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Honda Models Covered & Key Technical Specifications

1996-2004 Honda XR400R (Service Manual) Shop manual for the Honda XR400R with detailed procedures for component removal/installation and system troubleshooting. Ref: 61CT000 | Series Engine Unit.

  • Verified Energy Draw: 38.5 kg signifies the total engine weight Framework.
  • Key Temperature Range: For optimal operation, 85.0 x 70.0 mm establishes the environmental limit Topology.
  • Prescribed Speed Rating: 397 cc -- signifies the displacement capacity Standards.
  • Nominal Shipping Weight: The engine requires 38.5 kg for standard operation Margin.
  • Design Clamp Forces: Maximum throughput reaches 9.3:1 Protocol.
  • Designated Consumption Data: For optimal operation, 100-142 psi establishes the compression limit Bounds.
Technical Specifications
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Document Number / Seller:
26125 / Amy Perez
File Size:
49.71 MB
File Type:
PDF
Language:
English
Pages:
275
Printable:
Yes
Category:
Motorbike
Last updated / verified
Dec 1, 2025

Honda Manual Features & Content Preview

In-Depth Engineering Training Manual: Motorcycle The Original: Honda XR400R Repair Manual 1996–2004 Procedure-Library

Product-Line: XR400R / Repair-Classification: Motorcycle Service / Architecture-Focus: Engine Systems.

The service manual covers removal and installation of the engine, as well as specific component procedures for the transmission, shift fork/shift drum, and crankshaft/balancer. Other components serviced with the engine in the frame include the cylinder head, cylinder/piston, clutch, primary drive gear, gearshift linkage, kickstarter, and oil pump.

Procedures documented include engine removal and installation, clutch components service, transmission disassembly and assembly, and crankshaft/balancer servicing.

Technical Specs Table (3-Column): Specification Diagnostic-Logic Framework
Engine Dry Weight 38.5 kg (85 lbs) N/A
Engine Oil Capacity at Disassembly 2.2 L (2.3 US qt, 1.9 Imp qt) N/A
Torque Values Various N·m and kgf·m specifications provided for critical fasteners N/A

TOC Summary Block: The service manual covers:

  • Engine Removal/Installation
  • Clutch, Kickstarter, Gearshift Linkage
  • Crankshaft/Balancer
  • Transmission
  • Front Wheel/Suspension/Steering

This manual provides essential information for maintaining and repairing your Honda XR400R. It details procedures for engine removal and installation, clutch, transmission, and crankshaft/balancer servicing. Specific sections cover front wheel, suspension, and steering system maintenance, ensuring comprehensive coverage for your motorcycle's key components. The manual also documents procedures for the fuel system, lubrication system, and electrical system.

This repair manual documents torque specifications for critical engine components to ensure proper structural misalignment prevention.

Manual FAQ, Purchase & Download Details

Can I find technical reference tables, valve clearance settings, and fluid capacity charts in this service manual? keyboard_arrow_down

Document includes extensive specification tables that cover technical reference categories such as lubrication systems, valve clearances, and fluid capacities for the listed models. These tables provide the standard and service limit values for maintenance and component assessment.

Which major motorbike systems are included in the chapter coverage of this service manual? keyboard_arrow_down

Manual covers comprehensive sections for the engine, lubrication system, fuel system, transmission, electrical system, and chassis components including suspension and steering.

What kind of visual aids and component breakdown diagrams appear in the manual? keyboard_arrow_down

Document contains assembly illustrations, system diagrams, and exploded views throughout the various sections to show component locations. These visual resources assist in identifying parts and their relationships within the motorcycle assemblies.

Does the manual contain specification tables for tightening torques or fastener values? keyboard_arrow_down

Yes, the manual contains dedicated torque value tables for engine and frame components, listing both standard and critical fastener torque specifications.

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