1996-2004 Honda XR400R Repair Manual PDF

A comprehensive service and repair manual for the Honda XR400R off-road motorcycle. It covers the complete motorcycle: frame and body panels, maintenance, lubrication, fuel system, engine overhaul, clutch and kickstarter, transmission, crankshaft and balancer, wheels and suspension, brakes and electrical, with a wiring diagram and troubleshooting.

This manual applies to the Honda XR400R.

The manual covers many topics, including:

• General information, specifications, torque values and cable routing
• Frame, body panels and exhaust system
• Maintenance
• Lubrication system and fuel system
• Engine removal and installation
• Cylinder head, valves, cylinder and piston
• Clutch, kickstarter and gearshift linkage
• Alternator, transmission, crankshaft and balancer
• Front wheel, suspension and steering
• Rear wheel and suspension
• Hydraulic disc brake
• Electrical system, wiring diagram and troubleshooting

The manual is divided into the following sections:

1. General Information
2. Frame / Body Panels / Exhaust System
3. Maintenance
4. Lubrication System
5. Fuel System
6. Engine Removal / Installation
7. Cylinder Head / Valve
8. Cylinder / Piston
9. Clutch / Kickstarter / Gearshift Linkage
10. Alternator
11. Transmission
12. Crankshaft / Balancer
13. Front Wheel / Suspension / Steering
14. Rear Wheel / Suspension
15. Hydraulic Disc Brake
16. Electrical System
17. Wiring Diagram
18. Troubleshooting
19. Index

The electronic manual is a 276-page PDF, available to download right after checkout. It is a page-image (scanned) file, so it is not text-searchable; use the contents pages at the front, or the clickable chapter bookmarks. It works on Windows, Mac, tablets and phones, and you can print only the pages you need.

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