1996-2004 Honda XR400R Service Manual (P/N 61CT000)

• Covers 1996–2004 Honda XR400R off-road motorcycles, detailing specific carburetor tuning variations for 1996–1997 and post-1997 models
• Official Honda publication (Ref: 61CT000) spanning 275 pages of comprehensive reference data
• Features 47 distinct exploded-view component diagrams, 8 detailed electrical wiring schematics, and 3 comprehensive torque-specification tables to support detailed repair planning

Content Organization and Workshop Utility

This factory manual delivers a structured diagnostic framework designed to streamline your workflow in the garage. Initial chapters map out model identification, precise tool requirements, and essential safety protocols to ensure proper handling of heavy motorcycle components before beginning any serious teardown. The documentation then walks through the exact removal and installation sequences for major body panels, the fuel tank, and the exhaust system.

Engine Diagnostics and Chassis Reference

The engine sections supply crucial reference points for the top-end, tracking specifications for the cylinder head, valve train, and piston components. Dedicated chapters catalog the lubrication system—including oil pump and oil cooler diagnostics—alongside fuel system data that breaks down carburetor disassembly and regional pilot screw adjustments. Whether you are reviewing transmission clutch assemblies or kickstarter linkages, the powertrain and chassis documentation clearly outlines suspension, steering head bearings, and brake system reference data. Reviewing this comprehensive material is vital for safe and accurate repair preparation.

Crucial Specifications and Tolerances

Technical figures are central to assessing component wear and guiding final assembly. The document catalogs precise wear limits for critical engine and drivetrain parts, while torque values are categorized by system to verify fasteners reach factory-prescribed levels. Key figures include a standard valve clearance of 0.10 mm (intake) and 0.12 mm (exhaust). The engine dry weight sits at 38.5 kg (85 lbs), and baseline cylinder compression ranges from 686 to 980 kPa (100–142 psi). Always observe strict workshop safety standards and verify these baseline figures against your specific machine conditions to prevent mechanical failure or personal injury during servicing.