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Honda XR400 Manual

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______________________________________________
Thank you for purchasing a Honda motorcycle. For your safety and comfort, please familiarise
yourself with this manual before riding.
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Summary of Contents for Honda XR400

  • Page 1 ______________________________________________ Thank you for purchasing a Honda motorcycle. For your safety and comfort, please familiarise yourself with this manual before riding.
  • Page 2  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. rider. Note that you cannot carry a passenger for the first 12 months after obtaining your motorcycle license.

  • Page 3: Safety Warnings

    * 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.

  • Page 4: Table Of Contents

    Contents _____________________________________________ SAFETY WARNINGS………………………… Turn signal switch…………………………. CONTENTS……………………………………. .……..………….. 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……….. Instruments………………………………….
  • Page 5 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………...………………..

  • Page 6: For Your Own Safety

    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.
  • Page 7 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.

  • Page 8: Protective Apparel

    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.

  • Page 9: Riding Tips

    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.

  • Page 10: Luggage & Modifications

    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. Be the controllability and exhaust noise, which careful in terms of loading and securing may affect the durability of the motorcycle.

  • Page 11: Parking

    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.

  • Page 12: Parts Location

    Parts Location _______________________________________________...
  • Page 13 Parts Location _____________________________________________...

  • Page 14: Instruments And Indicators

    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.

  • Page 15: Indicators / Warning Lamps

    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.

  • Page 16: Switches

    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”...

  • Page 17: Headlamp Dimmer Switch

    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.

  • Page 18: Engine Stop Switch

    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.

  • Page 19: Starter Button

    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.

  • Page 20: Turn Signal Switch

    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 <...

  • Page 21: Features / Accessories

    Features / Accessories _______________________________________________ Steering Lock To prevent theft, always apply the Steering lock when parking. Use of a chain lock or similar device is also recommended. To engage the lock 1. Turn handlebar fully to the left or right. 2.

  • Page 22: Helmet Holder

    Features / Switches _______________________________________________ Helmet Holder The helmet holder may only be used when the motorcycle is parked. Using the holder will interfere with the operation and may damage the motorcycle. Also it will damage the helmet, reducing its protection. To use the helmet holder 1.

  • Page 23: Document Bag

    Features / Switches _______________________________________________ Document Bag The document bag is located in the Tool Kit Holder, on the Rear Fender. Keep the owners manual and the service manual in a plastic bag and store in the Tool Kit Holder. Do not overload the Tool Kit Holder as it may cause the Rear Fender to crack or break.

  • Page 24: Fuel Supply

    Fuel System _______________________________________________ The XR400M uses only unleaded petrol. Refueling Always stop the engine before refueling and keep well clear of naked flames, sparks or 1. Lift up the key cover. Insert the ignition heat sources. key and turn to the right to open the fuel fill cap.

  • Page 25: Fuel Cock

    Fuel System ______________________________________________ 2. Do not fill higher than the bottom of the Fuel Cock filler neck (see diagram) or petrol may seep out through the breather hole on The fuel cock lever has three positions: the fuel tank cap. “ON”...

  • Page 26: Basic Operation

    Basic Operation ______________________________________________ Starting the Engine Engine exhaust fumes contain carbon monoxide and other harmful substances. Always start the engine in well ventilated  This model is equipped with an area. automatic ignition cut off circuit Refer to pages. 24 ~ 26 for the starting that stops the engine procedure.
  • Page 27 Basic Operation ______________________________________________ Starting Procedure  When the engine is cold: 1. Check the engine stop switch is in RUN position. 2. Check the fuel cock lever is in ON position. 3. Turn the ignition ON. 4. Shift the gear change pedal to neutral position and check that the neutral indicator is ON.
  • Page 28 Basic Operation _______________________________________________ Starting Procedure  When the engine is hot: 1. Check the engine stop switch is in the “RUN” position. 2. Check the fuel cock lever is in the “ON” position. 3. Turn the ignition switch “ON”. 4. Shift the gear change pedal into neutral position and check the neutral indicator is “ON”.

  • Page 29: Changing Gear

    Basic Operation _______________________________________________ Changing Gear The XR400M has a five speed return gear change, Down for First Gear and up for all other gears.:  Release the throttle and fully squeeze the clutch lever before selecting / changing gear.  Operate the gear shift pedal gently but firmly using your toe (excessive force may damage the gear change system).

  • Page 30: Riding Tips

     To save fuel and prolong the life of the motorcycle, avoid rapid acceleration or deceleration. Advice If you notice any unusual sound or other problems, contact an authorized HONDA dealer as soon as possible.  Accelerate as gently as possible.  Always observe the speed limit. Running In...
  • Page 31 Basic Operation _______________________________________________ Maximum Speed Changing down the gears 95 km/h – 3 75 km/h – 2 Changing down gears provides greater 50 km/h acceleration in situation such as overtaking. – 1 35 km/h Avoid changing down at high speed, which can damage both the engine and the transmission by running the engine at excessively high rpm.

  • Page 32: Braking

    Basic Operation _______________________________________________ Braking  For optimum braking performance, apply  Braking performance may be affected by front and rear brakes simultaneously. puddles and wet weather. Always test the brakes gently after riding through  Brake as gently as possible to avoid such conditions (keep clear of other traffic and slow down first).
  • Page 33 Basic Operation _______________________________________________ Engine braking Engine braking can be used to reduce speed instead of, or in combination with, the brakes by simply retarding the throttle. Shift down gears if necessary. Avoid abrupt shift down or the motorcycle may fishtail and transmission damage may occur.

  • Page 34: Maintenance Safety Tips

    Maintenance Safety Tips _______________________________________________ Maintenance Safety Tips    Park on a flat and stable surface using  Stop the engine and remove the key when servicing. the side stand.
  • Page 35 Maintenance Safety Tips _______________________________________________   Wait for the engine, the muffler and Engine exhaust fumes contain the exhaust pipe to cool before starting carbon monoxide and other harmful work. substances. Do not run the engine in poorly ventilated area such as a closed workshop.
  • Page 36 Maintenance Safety Tips _______________________________________________  Always use proper tools.  If the motorcycle requires test  Any servicing, repair or adjustment riding, conduct in a safe place, away should be carried out by an authorized from other traffic. Honda dealer.

  • Page 37: Maintenance

    Maintenance _______________________________________________  To ensure the safety and comfort of  Inspection and maintenance procedures riding your motorcycle, it is required to and requirements are described on the inspect some items daily and service the following pages. machine regularly. After the first month………………….. 36 Replacement parts……………………...

  • Page 38: After The First Month

    After the first month Replacement parts The first service after one month (or Use only genuine Honda parts and oil when 1000km) is crucial to the life of the engine. servicing the motorcycle. Contact an authorized Honda dealer for all Honda parts and oil are designed service requirements.

  • Page 39: Daily Inspection

    Maintenance _______________________________________________ Daily (pre-ride) Inspection Checklist Daily (pre-ride) Inspection  Brakes - Lever free play (hydraulic) All motorcycle riders are advised to carry - Pedal free play (hydraulic) out a daily pre-ride inspection to ensure - Braking performance safe and comfortable riding. - Brake fluid level ...

  • Page 40: Maintenance Parts Layout

    Maintenance _______________________________________________ Maintenance Parts Layout Maintenance procedures and guidelines are given in “Basic Maintenance” pages of this manual.
  • Page 41 Maintenance _______________________________________________...

  • Page 42: Regular Service

    It is your responsibility to have your motorcycle serviced by an authorized Honda dealer.  Contact your Honda dealer to arrange servicing.  If you are checking the motorcycle by yourself, do not carry out work beyond your knowledge and skill, for your own safety.

  • Page 43: Maintenance Schedule

    The following Maintenance Schedule specifies all maintenance required to keep your motorcycle in peak operating condition. Maintenance work should be performed in accordance with standards and specifications of Honda by properly trained and equipped technicians. Your authorised Honda dealer meets all of these requirements.
  • Page 44 Maintenance _______________________________________________ FREQUENCY ODOMETER READING [NOTE (1)] X 1,000km *Refer X 1,000mi Service Manual ITEM NOTE MONTH DRIVE CHAIN EVERY 1,000km (600mi) I, L DRIVE CHAIN SLIDER BRAKE SHOE / PAD WEAR BRAKE SYSTEM BRAKE LIGHT SWITCH HEADLIGHT AIM CLUTCH SYSTEM SIDE STAND SUSPENSION NUTS, BOLTS, FASTENERS...
  • Page 45 TO THE OFFICIAL HONDA SHOP MANUAL.   IN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY YOUR AUTHORISED HONDA DEALER. Honda recommends that your authorised Honda dealer should road test your motorcycle after each periodic maintenance is carried out. NOTES: At higher odometer readings, repeat at the frequency interval established here.

  • Page 46: Basic Maintenance

    Do not carry out any work beyond your knowledge and skill, and always use proper tools. Contact an Authorised Honda Dealer if you do not have proper tools or skills required for a particular job.

  • Page 47: Engine Oil

    Maintenance _______________________________________________ Engine Oil Note: The engine, the muffler and the exhaust pipes are extremely hot after stopping the engine. Be careful to avoid burn injuries. Oil Level Prior to starting the engine and checking the oil level, please carry out the following checks: 1.

  • Page 48: Adding Oil

    Do not mix different brands / and or grades of oil and do not use oil that doesn’t match the chart, regardless of the Genuine Honda oil for 4-stroke motorcycle. 10W – 30 ( General use ) quality. Use of such oil may cause engine Honda GN4 damage or loss of performance.
  • Page 49 Maintenance _______________________________________________ Temperature and Viscosity Oil change intervals. Choose the engine oil corresponding to the Initial: 1,000km After the first change: Every 6000km atmospheric temperature in your riding Contact an Authorized Honda Dealer for the area. oil change.

  • Page 50: Oil Quantity Check

    Maintenance Oil Quantity Check: 2. After warm up, let the motorcycle idle 1. Park the motorcycle on a flat, level for about one minute, while holding surface. Start the engine and warm it the motorcycle upright. up, particularly in cold climates. Warm up can be done with the motorcycle on its sidestand.
  • Page 51 Maintenance _______________________________________________ 3. Stop the engine and remove the oil dipstick straight way. 4. Wipe the oil from the dipstick. 5. Hold the motorcycle upright and insert the dipstick – Do Not Screw in. 6. The oil level should be between the Min and Max lines –...

  • Page 52: Drive Chain

    Never ride the motorcycle if the slack is 60mm or more. Roll the motorcycle back and forward to observe the chain. If the chain is jerky or noisy, have it serviced / replaced. Contact an Authorized Honda Dealer for the adjustment or the replacement.

  • Page 53: Drive Chain Lubrication / Cleaning

    Maintenance _______________________________________________ “Genuine Honda Chain Oil” < Lubrication and Cleaning > 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.

  • Page 54: Brakes / Clutch

    Rear Brake Reservoir. 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.

  • Page 55: Brake Pad Wear / Inspection

    Brakes / Clutch _______________________________________________ < Brake pad inspection > 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.

  • Page 56: Clutch Lever Free Play

    Brakes / Clutch _______________________________________________ Clutch < Free play in the clutch lever > 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).

  • Page 57: Clutch - Free Play Adjustment

    Brakes / Clutch _______________________________________________ < Free play adjustment > 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.

  • Page 58: Battery

    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.

  • Page 59: Battery Terminals

    Battery _______________________________________________ Cleaning the battery terminals Remove the battery (p. 58).  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.

  • Page 60: Battery Removal / Installation

    Battery _______________________________________________ < Battery Removal / Installation > Removal 1. Remove the Left Side Cover. 2. Disconnect the negative lead from the battery terminal. 3. Disconnect the positive lead from the battery terminal. 4. Remove the bolts from the Battery Retainer.

  • Page 61: Fuses

    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.
  • Page 62 Battery / Fuses _______________________________________________ Fuse Box 1. Remove the Left Hand Side Cover. 2. Open the fuse box cover. 3. Locate the blown fuse from the fuse diagram. Replace with one of the spare fuses inside the fuse box. 4. Close the fuse box and install the side cover.

  • Page 63: Tyres

    Tyres _______________________________________________ Tyres < Tread > 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.

  • Page 64: Replacement Tyres

    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.

  • Page 65: Air Filter

    2. Release the Air Cleaner Element Retainer Clip. 3. Remove Air Cleaner Element. 4. 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.

  • Page 66: Cleaning

    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.
  • Page 67 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.

  • Page 68: Damper Unit

    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.

  • Page 69: Colour Label

    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.

  • Page 70: Genuine Honda Mufflers

    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.

  • Page 71: Frame Serial Number (Vin)

    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.

  • Page 72: Troubleshooting

    Engine Troubleshooting _______________________________________________ < If the Engine stalls, or does not start, Breather Cleaning Procedure check the following > 1. Place an oil pan under the Breather Drain. 1. That the engines is started in 2. Remove the Drain Plug and remove accordance with the starting procedure in this manual.

  • Page 73: Specifications

    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...
  • Page 74 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...
  • Page 75 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...

  • Page 76: Noise Warning

    _______________________________________________ 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...

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