1996-2004 Honda XR400R Service Manual

Technical Scope of the 1996–2004 Honda XR400R Service Manual

• Covers 1996–2004 Honda XR400R off-road motorcycles, including specific carburetor tuning variations for 1996–1997 and post-1997 models
• Official Honda publication Ref: 61CT000
• Contains 47 distinct exploded-view component diagrams, 8 detailed electrical wiring schematics, and 3 comprehensive torque-specification tables
• File delivers as a direct download the moment payment clears
• Indexed PDF search covers every chapter and appendix
• This 275-page factory publication provides the exact service procedures and maintenance data required for professional-level engine and chassis upkeep

Manual Walkthrough and Content Organization

This 1996–2004 Honda XR400R service manual follows a structured diagnostic and maintenance format. Initial chapters detail model identification, general safety precautions, and precise tool requirements for service. The documentation proceeds to cover removal and installation for major body panels, the fuel tank, and the exhaust system.

The engine sections provide detailed data for the top-end, including cylinder head, valve train, and piston specifications. Detailed chapters address the lubrication system, including oil pump and oil cooler service, alongside fuel system tuning, which covers carburetor disassembly and pilot screw adjustment for different regional types. Transmission, clutch, and kickstarter linkage procedures complete the powertrain section, while chassis documentation addresses suspension, steering head bearings, and brake system maintenance.

Specification Highlights and Technical Reference

Technical specifications are provided to facilitate accurate component assessment and assembly. The document includes detailed wear limits for critical engine and drivetrain components to assist in assessing serviceability. Torque values are cataloged by system, ensuring fasteners are secured to factory-prescribed levels.

Standard valve clearance is 0.10 mm for intake and 0.12 mm for exhaust. The engine dry weight is specified at 38.5 kg (85 lbs). Cylinder compression is documented at 686–980 kPa (100–142 psi). These technical figures serve as primary references for verifying engine state and chassis setup. All service data shown here is for reference only — qualified technicians and the original OEM documentation remain the authoritative source for any hands-on work. An official 275-page Honda factory service manual covering the 1996–2004 XR400R, documenting engine, chassis, electrical, and carburetor-tuning specifications for the entire production run.

Document Reference: Ref: 61CT000