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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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.
Professional Workshop Service Manual & Technical Specifications
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.
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