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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Document Details

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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

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.

Manual Description & 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.

FAQ

What are the **proper** clearance measurements for the Honda XR400R? keyboard_arrow_down

0.016 - 0.052 mm (0.0006 - 0.0020 in) is the clearance for the rocker arm to shaft for the Honda XR400R, with a service limit of 0.10 mm (0.004 in).

Specify the **standard** torque specifications for the Honda XR400R. keyboard_arrow_down

26 N·m (2.7 kgf·m, 20 lbf·ft) is the standard torque for the cylinder head nut on the Honda XR400R, applied to threads and seating surfaces.

What is the **necessary** safety precautions when working with the fork seals? keyboard_arrow_down

Handle the fork cap carefully to prevent the needle of the cap from being damaged, as this will affect the rebound damping force.

Calculate the **recommended** lubrication requirements for the valve guides. keyboard_arrow_down

5.46 mm (0.215 in) is the standard O.D. for the intake valve stem, with a service limit of 5.44 mm (0.214 in) for the exhaust valve stem.

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