Honda XR400R Repair Manual 1996-2004

This Clymer DIY repair and workshop manual covers 1996-2004 Honda XR400R off-road bikes. Complete motorcycle maintenance, service and repair information for the do-it-yourself mechanic. Every system is covered in detail, accompanied by hundreds of clear photos that provide a visual step-by-step guide. You can use this manual to perform basic routine maintenance on your dirtbike, all the way to a complete tear-down and rebuild.

Book Excerpt

IGNITION TIMING

The XR400R is equipped with a capacitor discharge ignition (CDI), which has not moving parts or provision for adjusting the timing. However, The ignition timing can be checked as a troubleshooting aid. If the ignition timing is incorrect, there is a defective component in the ignition system. WARNING: Never start and run the motorcycle in a closed area. The exhaust gases contain carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide levels build quickly in enclosed areas and can cause unconsciousness and death in a short time. When running the engine, always do so in a well-ventilated area. NOTE: To check the timing, a separate 12-volt battery will be required to operate the timing light.

1. Start the engine and warm to normal operating temperature. Turn the engine off.
2. Place the bike on the sidestand.
3. Remove the timing hole cap (Figure 33) from the left crankcase cover.
4. Connect the timing light battery leads to a separate 12 volt battery. Connect the timing light inductive lead to the spark plug wire.
5. Start and run the engine at idle speed (1200-1400 rpm).
6. Point the timing light at the crankcase cover timing hole (Figure 34). The ignition timing is correct when the F mark on the flywheel aligns with the index notch on the crankcase cover (Figure 35). Turn the engine off.

FRONT SUSPENSION AND STEERING

FRONT FORK ADJUSTMENT The front fork can be adjusted to suit rider weight and riding conditions. Variables, such as fork oil level and compression and rebound adjustments, can be modified to overcome various handling complaints. When setting a suspension variable, make one adjustment at a time and then test ride the bike. Keep a record of the changes and how they affect the handling. Work in a systematic manner to avoid confusion and return to the original base settings if handling deteriorates. Make sure the steering stem, fork and front wheel bearings are in good condition before making any adjustments. AIR PRESSURE These forks are designed to operate without air pressure. Before riding the bike, bleed the air out of the fork tubes as follows:

1. Support the bike with the front wheel off the ground.
2. Loosen the air screw (A, Figure 87) in the fork cap to release built-up air pressure. Then tighten the screw. Repeat for the other fork tube.

Subject: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004 Honda XR400R service, maintenance, repair. ISBN-10: 0892879246 | ISBN-13: 9780892879243 | Clymer M320-2