Honda Xr400r Shop Manual
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Honda Xr400r Shop Manual
. Thank you for purchasing a Honda motorcycle. For your safety and comfort, please familiarise yourself with this manual before riding. Service requirements Filling out the purchase receipt and The vehicle is designed to carry a ensuring your new Honda is registered maximum of two people, including the for warranty card. Note that you cannot carry a passenger for the first 12 months after obtaining your motorcycle license. When re-selling the vehicle please hand this Note: Potential of minor injury. Manual and the maintenance record to the next owner.
Honda MPE reserves the right to alter Other symbols: specifications and make other changes at any time without notice or obligation. Contents SAFETY WARNINGS Turn signal switch.
FOR YOUR OWN SAFETY.Features / Accessories Steering lock. Before Riding. Protective Apparel. Helmet holder Riding Tips. Document bag. Luggage & Modifications Tool kit holder Parking. PARTS LOCATION INSTRUMENTS AND INDICATORS.
Damper Unit For our environment. Colour label. Brakes / Clutch Brake fluid level. Genuine Honda mufflers.
Brake pad wear / inspection.Frame serial number (VIN). Clutch lever free play Troubleshooting. Clutch - free play adjustment Crankcase breather cleaning Specifications.
For Your Own Safety Before Riding The topics described here are the basic Please conduct the daily inspection. Instructions for handling the vehicle. Keep the vehicle clean at all times and Please follow the instructions from your inspect the specified items. For Your Own Safety Please stop the engine and keep Exhaust gas is toxic. Operate the clear of fire when refueling. Engine in a well ventilated place.
For Your Own Safety Protective apparel Caution Both rider and passenger are required Wearing the helmet incorrectly by law to wear a helmet. Secure the increases the risk of serious injury or strap properly.
Helmets approved to death in an accident. AS1698 are the only legal helmets in Both rider and passenger must wear Australia. For Your Own Safety Riding Tips Keep both hands on the handlebars Do not jerk the handlebars or and both feet on the foot rests at all attempt to ride with only one hand. This times whilst in motion. Safety rule applies to any two-wheeled vehicle. For Your Own Safety Luggage Modification Any modification which affects the function Controllability and stability of the and the structure of the vehicle may affect vehicle changes by loading luggage.
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Be the controllability and exhaust noise, which careful in terms of loading and securing may affect the durability of the motorcycle. For Your Own Safety Parking Park on stable and flat ground. Do not obstruct the traffic flow when parking your vehicle.
Park the vehicle so as to keep the hot muffler away from other people. While running the engine or immediately after shutdown, do not touch the engine or muffler. Parts Location. Parts Location. Instruments and Indicators Instruments and Indicators Instruments Speedometer Indicates the travelling speed in Kilometres Per Hour.
Ride safely and observe the legal speed limit. Odometer Shows accumulated distance traveled in kilometres.
The black number on white background shows 100m increments. Tripmeter Shows distance traveled per trip. Instruments and Indicators Direction Indicator Flashes when either turn signal is ON. High Beam Indicator Illuminates if the high beam is selected. Neutral Lamp Illuminates if the engine is in neutral gear and the main switch key is at ON position. Switches Ignition Switch The ignition switch operates the electrical circuits.
Do not touch the switch whilst riding. Turning the ignition switch to “OFF” or “LOCK” disables the electrical system. Advice The headlamp turns “ON” when the ignition switch is “ON”. Thus the battery will become flat if the ignition switch is Remove left “ON”. Switches Headlamp Dimmer Switch Push the corresponding side of the switch.
(Hi) High beam (Lo) Low beam Select LO (low beam) during the day or when other traffic is approaching. Switches Engine Stop Switch The engine stop switch allows you to stop the engine immediately in an emergency situation. The engine stop switch should be left in RUN position during normal riding and used only in case of emergency. Switching between RUN and OFF whilst riding leads to unstable engine running and riding instability. Switches Engine Start Button It activates the starter motor to crank the engine while the switch is pushed. Advice The starter motor consumes considerable power.
Avoid long cranking to prevent flattening the battery. The starter motor cannot be engaged if the engine stop switch is OFF.
Switches Turn Signal Switch The turn signal switch is used to operate the turn signal lamps when turning left or right or changing lanes. The ignition switch must be “ON”. Push the switch to the direction you are turning (LEFT Chain Oil: Place the motorcycle on the side stand and Or gear oil (#80 #90). Clean mud or dirt from the chain and sprocket. Move the motorcycle back and forward to clean entire chain. Rear Brake Reservoir.
Honda Xr400 Workshop Manual
If the fluid level is below the minimum, brake pads may be worn. Check the pads for wear or damage. If the brake pads are fine, there may be a leak in the brake system. Contact your Honda Dealer. Brakes / Clutch Honda recommends that brake pads be inspected regularly, between services. Inspect the brake pads from underneath the calipers.
If the wear limit line is worn through to the side of the brake disc, replace the pads on both sides. Brakes / Clutch Clutch Squeeze the clutch lever until resistance is felt.
Measure the distance traveled at the tip of the clutch lever with a ruler. Free play: 10 20mm Adjust the free play if necessary (p.55). Brakes / Clutch Adjust the free play with the adjusters on either the clutch lever and/or the clutch end of the clutch cable. Loosen the lock nut to use the adjuster. After adjusting, tighten the lock nut.
Check the free play again. Battery Battery The XR400M is equipped with a Caution maintenance free battery. Battery fluid level The diluted sulphuric acid electrolyte is check or refill are not required.
Keep the highly corrosive and can cause severe battery terminals free of dirt and corrosion. Burns if it comes in contact with the eyes or skin. Battery Cleaning the battery terminals Remove the battery (p. Mild corrosion (white powder on the terminals): Wipe after applying warm water. Severe corrosion: Use sandpaper or a wire brush.
Coat the terminals lightly with Petroleum Jelly or other “non-conductive” grease and install the battery. Battery Removal 1. Remove the Left Side Cover. Disconnect the negative lead from the battery terminal.
Disconnect the positive lead from the battery terminal. Remove the bolts from the Battery Retainer. Locate and repair the fault before installing a new fuse. Advice Replace the electrical parts only with genuine Honda accessories. Other parts can cause fuses to blow or flatten the battery. Battery / Fuses Fuse Box 1. Remove the Left Hand Side Cover.
Open the fuse box cover. Locate the blown fuse from the fuse diagram.
Replace with one of the spare fuses inside the fuse box. Close the fuse box and install the side cover. Tyres Tyres Tyres should be kept in good condition and Tyres should be replaced as soon as wear maintained at the rated pressure at all indicators start to appear on the tyre wall, or times. Worn tyres should be replaced when the tread on the centre of the tyre immediately. Use of other types can Use of tyres other than the affect handling and stability.
Designated tyres in the table can Contact an Authorized Honda Dealer when affect handling and stability and replacing a tyre. Could cause serious injury or death. Release the Air Cleaner Element Retainer Clip. Remove Air Cleaner Element.
Replace in reverse order – Ensure that element is correctly seated to avoid dust entry. Use only Genuine Honda Replacement Parts, which are available at your Authorized Honda Dealer. Cleaning To prevent internal rust and Polish painted surfaces and plastic parts potential starting problems, keep water gently.
Out of the muffler. Strong rubbing with wax or polishing compounds can wear down the paint Keep brake parts dry.
Water in the coating and cause discoloration. Cleaning Aluminum Parts (Aluminum wheel) Parts made out of Aluminum Alloy should be handled carefully. Aluminum parts corrode if exposed to salt or mud.
Sponge off salt water, road salt and other dirt immediately using mild detergent. Rinse with plenty of water and dry with soft cloth. Nitrogen Gas which should be released handle used batteries, tyres and engine oil prior to disposal. Contact an Authorized properly in terms of environmental matters. Honda Dealer when the damper units require replacement. Warning Do not throw the damper unit into fire or disassemble the unit. Colour label Colour Label When ordering coloured parts, quote the model name, colour and code on the colour label.
The colour label is located on the frame under the seat. Genuine HONDA Mufflers Genuine Honda Mufflers Use only genuine Honda mufflers with engraved Honda logo on the rear. Changing the Muffler may render this motorcycle in contravention of Noise Emission Regulations.
Changing the Muffler may also cause this motorcycle to run incorrectly, and engine damage may occur. Vehicle Identification Numbers Vehicle Identification Number (VIN) Engine Number The VIN is required when ordering parts When ordering engine parts, the engine and registering your motorcycle, and can number can also be required, to identify also be helpful if the motorcycle is stolen. Correct engine model. Engine Troubleshooting 1. Place an oil pan under the Breather Drain.
Honda Xr400r Service Manual
That the engines is started in 2. Remove the Drain Plug and remove accordance with the starting procedure in this manual. Specifications Type ND08 Overall length 2140mm Overall width 810mm Overall height 1140mm Wheelbase 1450mm Engine type / volume 4-stroke, petrol / 0.397L Dry weight 145kg Maximum capacity 2 People 110/70 – 17M/C 54H Front Tyre size 140/70R – 17M/C 66H Rear Minimum ground clearance 220mm. Specifications Ignition system Ignition timing BTDC 8° / 1400rpm Idling speed 1300rpm DPR8Z Spark plugs N G K DPR9Z X24GPR-U D E N S O X27GPR-U 12V – 6AH Battery Reduction ratio between engine and gearbox 2.666 Clutch type Wet multi-plate coil spring Gearbox type Constant mesh transmission. Specifications 15 – 25mm Drive chain slack Tyre Driver Front 2.25 kgf/cm² pressure only Rear 2.50 kgf/cm² Driver and Front 2.25 kgf/cm² passenger Rear 2.50 kgf/cm² Engine Total capacity 2.2L Oil filter change 1.8L Oil change 1.7L 10 – 20mm Clutch lever free play Fuses Main fuse. Noise Control System (Australia Only) TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Owners are warned that the law may prohibit: (a) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new motorcycle for the purpose of noise control prior to.