Honda 2004 XR400R Page 166 Owner'S Manual Download

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(1)

(1) color label

157

Vehicle Identification

Color Label & Code

Technical Information

Quick Ref erence

The color label ( ) is attached to the frame
behind the left side cover (page

The color code is helpful when ordering
replacement parts. You may record the color
and code in the

section at the

rear of the manual.

03/05/20 10:19:51 31KCY680_166

Summary of Contents for 2004 XR400R

Page 1: ...ation available before printing Honda Motor Co Ltd reserves the right to make changes at any time without notice and without incurring any obligation This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is resold Honda Motor Co Ltd 2003 03 05 20 09 55 46 31KCY680_001 ...

Page 2: ...2004 Honda XR400R OWNER S MANUAL 03 05 20 09 55 49 31KCY680_002 ...

Page 3: ...and other information on labels and in this manual This information alerts you to potential hazards that could hurt you or others Of course it is not practical or possible to warn you about all hazards associated with operating or maintaining a motorcycle You must use your own good judgment You will find important safety information in a variety of forms including on the motorcycle preceded by a s...

Page 4: ...n t follow instructions Safety Messages A Few Words About Safety Safety Headings Safety Section Instructions such as Important Safety Reminders or Important Safety Precautions such as Motorcycle Safety how to use this motorcycle correctly and safely This entire book is filled with important safety information please read it carefully 03 05 20 09 56 01 31KCY680_004 ...

Page 5: ...s and modifications and the location of safety labels The location function and operation of the throttle brakes clutch and other basic controls The importance of wearing a helmet and other protective gear plus how to make sure you and your motorcycle are ready to ride Why your motorcycle needs regular maintenance what you need to know before servicing your Honda a maintenance schedule and instruc...

Page 6: ...otorcycle and how to be an environmentally responsible rider What to do if you have a flat tire your engine won t start etc ID numbers technical specifications and other technical facts Information on warranties and how to get Honda service manuals Handy facts about fuel engine oil tire sizes and air pressures Sequential listing of topics in this owner s manual 03 05 20 09 56 25 31KCY680_006 ...

Page 7: ...ant to observe the break in guidelines and perform all the pre ride and other periodic checks detailed in this manual We also recommend that you read the owner s manual before you ride It s full of facts instructions safety information and helpful tips To make it easy to use the manual contains a table of contents a detailed list of topics at the beginning of each section and an index at the back ...

Page 8: ...ve any questions or if you ever need a special service or repairs remember that your Honda dealer knows your motorcycle best and is dedicated to your complete satisfaction Please report any change of address or ownership to your Honda dealer so we will be able to contact you concerning important production information You may also want to visit our website at www honda com Happy riding 03 05 20 09...

Page 9: ...03 05 20 09 56 41 31KCY680_009 ...

Page 10: ...lp you ride your motorcycle safely Please take a few moments to read these pages This section also includes information about the location of safety labels on your motorcycle Important Safety Information 2 Loading Accessories Modifications 5 Loading 5 Accessories Modifications 7 Safety Labels 9 03 05 20 09 56 46 31KCY680_010 ...

Page 11: ...Your motorcycle is designed and manufactured for off road use only The tires are not made for pavement and the motorcycle does not have turn signals and other features required for use on public roads If you need to cross a paved or public road get off and walk your motorcycle across There is much that you can do to protect yourself when you ride You ll find many helpful recommendations throughout...

Page 12: ...is another major cause of motorcycle accidents Never ride beyond your personal abilities or faster than conditions warrant Remember that alcohol drugs fatigue and inattention can significantly reduce your ability to make good judgments and ride safely Developing off road riding skills is a gradual step by step process Start by practicing at low speeds in a safe area and slowly build your skills Pe...

Page 13: ...gets worse with every additional drink So don t drink and ride and don t let your friends drink and ride either It s important to keep your motorcycle properly maintained and in safe riding condition Having a breakdown can be difficult especially if you are stranded off road far from your base To help avoid problems inspect your motorcycle before every ride and perform all recommended maintenance ...

Page 14: ...rcycle More specific information on load limits accessories and modifications follows In addition exceeding the weight limits or carrying an unbalanced load can seriously affect your motorcycle s handling braking and stability Adding accessories or making modifications that change this motorcycle s design and performance can also make it unsafe Also the weight of any accessories will reduce the ma...

Page 15: ...eeds and follow these common sense guidelines Keep cargo small and light Make sure it cannot easily be caught on brush or other objects and that it does not interfere with your ability to shift position to maintain balance and stability Place weight as close to the center of the motorcycle as possible Do not attach large or heavy items such as a sleeping bag or tent to the handlebar fork or front ...

Page 16: ... accessory be sure to read the following information We strongly recommend that you use only genuine Honda accessories that have been specifically designed and tested for your motorcycle Because Honda cannot test all other accessories you must be personally responsible for proper selection installation and use of non Honda accessories Check with your dealer for assistance and always follow this gu...

Page 17: ... change its design or operation Such changes could seriously impair your motorcycle s handling stability and braking making it unsafe to ride We also advise you not to make any modifications or remove any equipment such as the USDA qualified spark arrester or emission control system components that would make the motorcycle illegal in your area 03 05 20 09 57 36 31KCY680_017 ...

Page 18: ...rcycle Some labels warn you of potential hazards that could cause serious injury Others provide important safety information Read these labels carefully and don t remove them If a label comes off or becomes hard to read contact your Honda dealer for a replacement 03 05 20 09 57 46 31KCY680_018 ...

Page 19: ...10 Motorcycle Safety 03 05 20 09 57 49 31KCY680_019 ...

Page 20: ... carefully before you ride It describes the location function and operation of all the basic controls on your motorcycle Component Locations 12 Fuel Valve 15 Choke Lever 16 Engine Stop Button 17 Front Brake Lever 17 Throttle 17 Clutch Lever 17 Shift Lever 18 Rear Brake Pedal 18 Kickstarter 18 Starter Decompressor Lever 18 Side Stand 19 Tripmeter 19 03 05 20 09 57 54 31KCY680_020 ...

Page 21: ...tripmeter starter decompressor lever front brake lever throttle engine stop button clutch lever 12 Component Locations Operating Controls 03 05 20 09 57 58 31KCY680_021 ...

Page 22: ...fuel valve choke lever shift lever side stand 13 Component Locations Operating Controls 03 05 20 09 58 03 31KCY680_022 ...

Page 23: ...kickstarter rear brake pedal 14 Component Locations Operating Controls 03 05 20 09 58 08 31KCY680_023 ...

Page 24: ...e fuel valve ON before attempting to start the engine allows fuel to flow from the fuel tank to the carburetor Turning the fuel valve OFF after stopping the engine prevents the flow of fuel from the fuel tank to the carburetor Turning the fuel valve to RES allows fuel to flow from the reserve fuel supply to the carburetor cont d ON OFF RES 03 05 20 09 58 17 31KCY680_024 ...

Page 25: ...o avoid running out of fuel with no reserve The choke lever is used for starting the engine page The choke increases the percentage of fuel in the fuel air mixture delivered to the engine Used to warm a cold engine immediately after starting with air temperature below 35 C 95 F Used for normal operation for restarting a warm engine or starting a cold engine with air temperature above 35 C 95 F Use...

Page 26: ...pm rotate the grip toward you To reduce engine rpm rotate the grip away from you The throttle will automatically return to the closed position engine idle when you remove your hand The clutch lever is used to disengage the clutch whenever you shift gears To operate pull the clutch lever in all the way before shifting then slowly release it after shifting The front brake lever is used to slow or st...

Page 27: ... lever to engage the next lower gear See page The rear brake pedal is used to slow or stop your motorcycle To operate depress the pedal For information on braking techniques see page The starter decompressor lever may be used if you experience starting difficulties or to help restart the engine while your motorcycle is rolling downhill To operate pull the lever in See page The kickstarter is used ...

Page 28: ...our motorcycle while parked page To operate use your foot to lower the stand Before riding raise the stand To operate pull the tripmeter reset knob out OFF and turn it until the meter shows all zeros then push the knob in ON The tripmeter is used to record the distance traveled USA miles Canada kilometers per trip or section of route 0 1 2 39 03 05 20 09 58 56 31KCY680_028 ...

Page 29: ...20 Operating Controls 03 05 20 09 58 58 31KCY680_029 ...

Page 30: ...ady to ride To help get you prepared this section discusses how to evaluate your riding readiness and how to perform the recommended pre ride inspection of your Honda Are You Ready to Ride 22 Protective Apparel 22 Is Your Motorcycle Ready to Ride 24 Pre ride Inspection 24 03 05 20 09 59 03 31KCY680_030 ...

Page 31: ...rotection is not possible wearing the proper gear can reduce the chance of injury when you ride Following are suggestions to help you choose the proper gear read this owner s manual make sure you understand all the safety messages know how to operate all the controls Before each ride we also suggest that you make sure you are in good physical and mental condition are free of alcohol and drugs are ...

Page 32: ...in strap that can be tightened securely An open face helmet offers some protection but a full face helmet offers more Regardless of the style look for a DOT Department of Transportation sticker in any helmet you buy USA only Always wear a face shield or goggles to protect your eyes and help your vision In addition to a helmet and eye protection we also recommend Riding pants with knee and hip pads...

Page 33: ...he motorcycle Use a gauge to check the air pressure Adjust if needed Also look for signs of damage or excessive wear page Make sure the spokes and rim locks are tight Also check the rims for damage page Look under the motorcycle for signs of leaking fluids fuel engine oil brake fluid Before each ride it s important to inspect your motorcycle and make sure any problem you find is corrected A pre ri...

Page 34: ...cking and snaps shut automatically when it is released in all steering positions page Squeeze the front brake lever and step on the rear brake pedal to check that the controls operate normally Check for proper freeplay page Check for looseness page Use a wrench to make sure all accessible nuts bolts and fasteners are tight Check the cable housings for wear Check the fittings for looseness Replace ...

Page 35: ...ing Clutch Lever Headlight Check for smooth operation and adjust if needed page Check for proper operation Remember be sure to take care of any problem you find or have your Honda dealer correct it before you ride 80 03 05 20 09 59 59 31KCY680_035 ...

Page 36: ...to make turns ride on hills etc see the booklet that came with your Honda USA only Safe Riding Precautions 28 Starting Stopping the Engine 29 Preparation 29 Starting Procedure 29 Starter Decompressor Lever 32 Flooded Engine 33 How to Stop the Engine 34 Shifting Gears 35 Braking 37 Parking 39 Post ride Inspection 40 For information about carburetor adjustment for riding at high altitude see page To...

Page 37: ...her motorcycles take time to become familiar with how this motorcycle works and handles Practice in a safe area until you build up your skills and get accustomed to your motorcycle s size and weight For your safety avoid starting or operating the engine in an enclosed area such as a garage Your motorcycle s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed are...

Page 38: ...he procedure for Normal Air Temperature 10 35 C 50 95 F Your motorcycle can be kickstarted with the transmission in gear by pulling in the clutch lever before operating the kickstarter Always follow the proper starting procedure described below Make sure that the transmission is in neutral Turn the fuel valve ON Pull the choke lever up all the way to fully ON cont d 1 1 A 03 05 20 10 00 26 31KCY68...

Page 39: ... Starting from the top of the stroke kick through to the bottom with a rapid continuous motion Do not operate the throttle Keep the throttle fully closed Immediately after the engine starts push the choke lever down to the detent position Warm up the engine by opening and closing the throttle slightly About a half minute after the engine starts push the choke lever down all the way to fully OFF If...

Page 40: ...ep under Pull the starter decompressor lever page in open the throttle fully and operate the kickstarter several times while pressing the engine stop button to clear the engine Release the starter decompressor lever Low Air Temperature 10 C 50 F or below Follow steps under Start the engine see step 3 under Warm up the engine by opening and closing the throttle slightly Continue warming up the engi...

Page 41: ...esistance Pull the starter decompressor lever in and push the kickstarter down again slowly about 1 4 to 1 2 of a full stroke Release the starter decompressor lever and kickstart your motorcycle in the usual manner The starter decompressor lever may also be used to help restart the engine while your motorcycle is rolling downhill Close the throttle Pull the clutch lever in and shift into 2nd or 3r...

Page 42: ...essor lever in again Wait until the motorcycle gains speed and release the lever Follow the starting procedure page Release the starter decompressor lever and engine stop button While pushing the engine stop button crank the engine several times with the kickstarter Open the throttle fully Pull and hold the starter decompressor lever Push the choke lever down all the way to OFF If the engine fails...

Page 43: ...to Stop the Engine Starting Stopping the Engine Basic Operation Riding To stop the engine shift into neutral push the engine stop button in and hold it in until the engine stops 03 05 20 10 01 16 31KCY680_043 ...

Page 44: ...If engine rpm is too high or you release the clutch lever too quickly your motorcycle may lurch forward Release the front brake Gradually open the throttle while you slowly release the clutch lever Depress the shift lever from neutral down to first gear Your motorcycle has five forward gears To start riding after the engine has been warmed and the side stand raised Close the throttle and pull the ...

Page 45: ...ottle and pull the clutch lever in completely before shifting Downshifting can help slow your motorcycle especially on downhills However downshifting when engine rpm is too high can cause engine damage To prevent transmission damage do not coast or tow the motorcycle for long distances with the engine off Learning when to shift gears comes with experience Upshift to a higher gear or reduce throttl...

Page 46: ...one or both wheels to slip Any wheel slip will reduce your control of your motorcycle cont d When riding in wet or raining conditions or on loose surfaces the ability to maneuver and stop will be reduced All of your actions should be smooth under these conditions Rapid acceleration braking or turning may cause loss of control For your safety exercise extreme caution when braking accelerating or tu...

Page 47: ...king by downshifting with intermittent use of both brakes When you brake to a stop pull the clutch lever in before stopping completely to prevent stalling the engine For support put your left foot on the ground first then your right foot when you re through braking 03 05 20 10 01 47 31KCY680_047 ...

Page 48: ...king Basic Operation Riding Lower the side stand to support your motorcycle If you re through riding for the day also turn the fuel valve OFF Always choose a level place to park 03 05 20 10 01 51 31KCY680_048 ...

Page 49: ...oroughly clean your motorcycle and remove any dirt mud brush rocks or other objects you may have picked up along the way After cleaning carefully inspect your motorcycle for leaks or damage Be sure to lubricate the drive chain page to prevent rusting 127 03 05 20 10 01 56 31KCY680_049 ...

Page 50: ...quired servicing and step by step instructions for specific maintenance tasks You ll also find important safety precautions information on oils and tips for keeping your Honda looking good The Importance of Maintenance 43 Maintenance Safety 45 Important Safety Precautions 45 Maintenance Schedule 47 Maintenance Record 51 Competition Inspection 52 For information about the exhaust emission and noise...

Page 51: ...moval 59 Seat Removal 60 Fluids Filters Fuel 61 Engine Oil 64 Air Cleaner 73 Crankcase Breather California only 76 Engine Throttle 77 Clutch System 80 Engine Idle Speed 83 Spark Plug 84 Spark Arrester 86 Chassis Suspension 88 Brakes 107 Wheels 112 Tires Tubes 118 Side Stand 122 Drive Chain 123 Headlight Taillight 130 Appearance Care 133 03 05 20 10 02 07 31KCY680_051 ...

Page 52: ...r parts even if you are able to make some repairs A well maintained motorcycle is essential for safe economical and trouble free riding It will also help reduce air pollution Careful pre ride inspections and good maintenance are especially important because your motorcycle is designed to be ridden over rough off road terrain To help you properly care for your motorcycle this section of the manual ...

Page 53: ...aintenance Servicing Your Honda Remember proper maintenance is the owner s responsibility Be sure to inspect your motorcycle before each ride and follow the Maintenance Schedule in this section 03 05 20 10 02 19 31KCY680_053 ...

Page 54: ... on how to perform some important maintenance tasks Some of the most important safety precautions follow However we cannot warn you of every conceivable hazard that can arise in performing maintenance Only you can decide whether or not you should perform a given task cont d Make sure the engine is off before you begin any maintenance or repairs This will help eliminate several potential hazards Be...

Page 55: ...over park it on a firm level surface using the side stand or a maintenance stand to provide support To reduce the possibility of a fire or explosion be careful when working around gasoline Use only a non flammable high flash point solvent such as kerosene not gasoline to clean parts Keep cigarettes sparks and flames away from all fuel related parts 03 05 20 10 02 31 31KCY680_055 ...

Page 56: ...ms are provided in this manual The Maintenance Schedule also includes items that involve more extensive procedures and may require special training tools and equipment Therefore we recommend that you have your Honda dealer perform these tasks unless you have advanced mechanical skills and the required tools Procedures for items in this schedule are provided in a service manual available for purcha...

Page 57: ...echnical information and tools Consult your Honda dealer Should be serviced by your Honda dealer unless the owner has the proper tools and service data and is mechanically qualified Refer to the official Honda Service Manual page In the interest of safety we recommend these items be serviced only by your Honda dealer inspect and clean adjust lubricate or replace if necessary clean adjust lubricate...

Page 58: ...iner Screen Throttle Operation Air Cleaner Crankcase Breather Spark Plug Valve Clearance Engine Oil Engine Oil Filter Engine Oil Strainer Screen in Down Tube Decompressor System Engine Idle Speed Should be serviced by your Honda dealer unless the owner has the proper tools and service data and is mechanically qualified Refer to the official Honda Service Manual page In the interest of safety we re...

Page 59: ...teners Wheels Tires Steering Head Bearings I L I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I Should be serviced by your Honda dealer unless the owner has the proper tools and service data and is mechanically qualified Refer to the official Honda Service Manual page In the interest of safety we recommend these items be serviced only by your Honda dealer 123 124 108 1...

Page 60: ...space under Notes to record anything you want to remind yourself about or mention to your dealer Of course if you find any problem while servicing your motorcycle be sure it is corrected as soon as possible 600 1 000 or 6 1 200 2 000 or 12 1 800 3 000 or 18 2 400 4 000 or 24 3 000 5 000 or 30 3 600 6 000 or 36 4 200 7 000 or 42 4 800 8 000 or 48 5 400 9 000 or 54 03 05 20 10 03 38 31KCY680_060 ...

Page 61: ...See your Honda dealer unless you are mechanically qualified and have the proper tools Refer to the Maintenance Schedule page for regular service intervals NOTE 48 1 2 3 4 5 6 all pre ride inspection items engine oil fuel line valve clearance engine idle speed carburetor choke contaminants deterioration damage or leakage correct clearance correct idle speed proper operation change replace adjust ad...

Page 62: ...steering head bearings front suspension rear suspension proper freeplay proper operation see NOTE 1 contamination or tears gap tightness proper heat range high tension terminal security free rotation of handlebar and steering stem nut tightness smooth operation air pressure oil capacity no oil leaks good boot condition smooth operation no oil leaks proper spring height adjust replace clean or repl...

Page 63: ...max length pin sprockets seat headlight tripmeter control cables engine mounting bolts smooth operation wear wear beyond service limit wear and secure installation security proper beam aim proper operation smooth operation kinks and correct routing tightness replace replace replace replace replace or tighten tighten adjust replace lubricate or replace tighten 89 89 110 125 126 60 130 19 03 05 20 1...

Page 64: ...uspension air cleaner left side cover chain slider side stand chain slipper frame oil drain bolt rear wheel axle drive chain crankcase oil drain bolt crankcase breather tube plug California only front brake hose 55 Component Locations Servicing Your Honda 03 05 20 10 04 22 31KCY680_064 ...

Page 65: ...retor front brake lever spark plug front wheel axle rim lock rear brake pedal kickstarter rim lock chain adjuster spark arrester lower clutch adjusting nut 56 Component Locations Servicing Your Honda 03 05 20 10 04 27 31KCY680_065 ...

Page 66: ...to on page The multi purpose wrench in the tool bag delivered with your motorcycle can be used to remove the spark plug Some repairs adjustments and part replacements may be performed with this tool You will need to provide your own tools to perform other owner maintenance 1 3 45 03 05 20 10 04 33 31KCY680_066 ...

Page 67: ...to remove the two bolts Pull the side cover out Installation Slide the top of the side cover under the bottom edge of the seat Align the tabs to the cutout of the rear fender Install the securing bolts and tighten them Tighten the seat bolt Use the same procedure to remove and install the left side cover 1 1 2 2 3 3 4 1 45 60 03 05 20 10 04 44 31KCY680_067 ...

Page 68: ...st be removed to service the air cleaner Removal Lift the D ring on each quick release fastener and turn it counterclockwise until it releases Installation Align the air cleaner housing cover with the air cleaner housing Push each quick release fastener into its slot lift its D ring and turn it clockwise until it is secure 1 1 2 1 45 03 05 20 10 04 52 31KCY680_068 ...

Page 69: ...load Removal Remove the two bolts securing the seat Slide the seat back Installation Align the locating slot under the front of the seat with the pin on the rear of the fuel tank Align the locating prongs on the bottom of the seat with the hooks on the frame Slide the seat into position Install the bolts and tighten them 1 1 2 1 2 3 4 2 3 4 5 45 03 05 20 10 05 04 31KCY680_069 ...

Page 70: ...ngine speed under normal load change brands of gasoline If pinging or spark knock persists consult your Honda dealer We recommend that you use unleaded fuel because it produces fewer engine deposits and extends the life of exhaust system components Never use stale or contaminated gasoline or an oil gasoline mixture Avoid getting dirt dust or water in the fuel tank Your engine is designed to use an...

Page 71: ...ther tube 3 steering stem nut 4 filler neck 3 2 4 1 62 Refueling Procedure Fuel Servicing Your Honda Fuel Tank Capacity including reserve Reserve Capacity To open the fuel fill cap pull the breather tube out of the steering stem nut Turn the fuel fill cap counterclockwise and remove it Add fuel until the level reaches the bottom of the filler neck Avoid overfilling the tank There should be no fuel...

Page 72: ...a After refueling turn the fuel fill cap clockwise until it is secure Insert the breather tube in the steering stem nut If you replace the fuel fill cap use only a genuine Honda replacement part 3 4 03 05 20 10 05 31 31KCY680_072 ...

Page 73: ...ard suggested oil 64 Oil Recommendation Engine Oil Servicing Your Honda Safety Precautions Refer to on page Using the proper oil and regularly checking adding and changing oil will help extend your engine s life Even the best oil wears out Changing oil helps get rid of dirt and deposits held in the engine Operating the engine with old or dirty oil can damage your engine Running the engine with ins...

Page 74: ...eled as energy conserving on the circular API service label Your motorcycle does not need oil additives Use the recommended oil Do not use oils with graphite or molybdenum additives They may adversely affect clutch operation Do not use API SH or higher oils displaying a circular API energy conserving service label on the container They may affect lubrication and clutch performance Do not use non d...

Page 75: ...art may be used when the average temperature in your riding area is within the indicated range JASO T 903 standard The JASO T 903 standard is an index to choose engine oils for 4 stroke motorcycle engines There are two classes MA and MB Oil conforming to the standard has the following classification on the oil container 03 05 20 10 06 00 31KCY680_075 ...

Page 76: ...ean Start the engine and let it idle for 5 minutes If the air temperature is below 10 C 50 F let the engine idle for an additional 5 minutes a total of 10 minutes An engine that is not warmed sufficiently may give an inaccurate low oil level reading During idling make sure your motorcycle is supported in an upright position to assure an accurate oil level reading Stop the engine cont d If the oil ...

Page 77: ...ce requirements Use a new genuine Honda oil filter specified for your model or a filter of equal quality The engine contains a crankcase oil level check bolt Remove the bolt and check that the level is flush with the lower edge of the hole If it is install and tighten the bolt start the engine and check the engine oil level If the crankcase oil level is low add the recommended engine oil before st...

Page 78: ... minutes Turn the engine off Wait 2 3 minutes for the oil to settle Remove the oil filler cap dipstick from the top of the frame Place a drain pan under the crankcase Remove the oil drain bolt on the down tube and the drain bolt on the left crankcase Changing the oil requires a torque wrench If you do not have it and the necessary skill we recommend that you have your Honda dealer perform this ser...

Page 79: ...al of drained fluids is harmful to the environment Pour the drained oil into a suitable container and dispose of it in an approved manner page Change the oil filter after draining the engine oil Remove the oil filter bolts and oil filter cover Frame drain bolt Crankcase drain bolt Install the oil drain bolts and tighten to the specified torque 7 8 9 4 145 3 03 05 20 10 06 44 31KCY680_079 ...

Page 80: ...the cover cont d Reinstall the oil filter cover making sure the bolts are tightened securely to the specified torque Oil filter bolt Position the spring against the engine crankcase and install a new oil filter with the rubber seal facing out away from the engine You should see the OUT SIDE mark on the filter body near the seal Check that the oil filter cover O ring is in good condition Discard th...

Page 81: ...t the engine Let it idle 5 minutes During idling support your motorcycle in an upright position on a firm level surface to assure an accurate oil level reading Stop the engine Remove the oil filler cap dipstick Add the recommended oil up to the upper level mark Do not overfill Reinstall the oil filler cap dipstick Check for oil leaks If the oil filter was replaced If the oil filter was not replace...

Page 82: ...ust mud and other impurities to pass into the engine Service the air cleaner more frequently if you ride in unusually wet or dusty areas Your Honda dealer can help you determine the correct service interval for your riding conditions Your motorcycle s air cleaner has very specific performance requirements Use a new genuine Honda air cleaner specified for your model or an air cleaner of equal quali...

Page 83: ...nging the air cleaner This can tear the foam Inspect for tears or cracks in the foam or seams of the air cleaner Replace the air cleaner if it is damaged Remove the air cleaner from its support Wipe the support clean Remove the air cleaner assembly Unhook the set spring Remove the air cleaner housing cover page Allow the air cleaner to dry thoroughly before applying oil A wet air cleaner will not ...

Page 84: ...eeze out any excess oil To keep your hands dry place the air cleaner in a clean plastic bag before spreading the oil into the air cleaner Install the air cleaner on its support Apply a thin coat of grease to the sealing surface of the air cleaner assembly Install the air cleaner with the lug on the holder aligned with the hole in the air cleaner Hook the set spring Install the air cleaner housing ...

Page 85: ...e Remove the crankcase breather tube plug from the tube and drain deposits Reinstall the crankcase breather tube plug Service more frequently if your motorcycle is ridden in the rain or often at full throttle Service the breather if you can see deposits in the transparent section of the drain tube 1 2 1 45 03 05 20 10 07 39 31KCY680_085 ...

Page 86: ...nda Safety Precautions Refer to on page Minor adjustments are generally made with the upper adjuster Upper Adjustment Check freeplay Freeplay Inspection If necessary adjust to the specified range Pull the rubber dust cover back Loosen the upper lock nut on the throttle cable mechanism Turn the upper adjuster cont d 1 2 3 2 1 3 1 45 03 05 20 10 07 52 31KCY680_086 ...

Page 87: ...eplay adjustment such as after replacing the throttle cables or removing the carburetor It is also used if you can not get the proper adjustment with the upper adjuster Loosen the lower lock nut on the cable Turn the lower adjuster Tighten the lock nut on the adjuster If you can t get the freeplay within the specified range contact your Honda dealer Tighten the lock nut Return the dust cover to it...

Page 88: ...hat the throttle assembly is positioned properly and the securing bolts are tight Inspect the condition of the throttle cables from the throttle grip down to the carburetor If the cable is kinked or chafed have it replaced Check the cables for tension or stress in all steering positions Lubricate the cables with a commercially available cable lubricant to prevent premature rust and corrosion 1 2 1...

Page 89: ...autions Refer to on page Upper Adjustment Minor adjustments are generally made with the upper clutch cable adjuster Pull the rubber dust cover back Loosen the upper lock nut Turn the upper clutch cable adjuster to obtain the specified freeplay Inspection Check freeplay Freeplay If necessary adjust to the specified range Improper freeplay adjustment can cause premature clutch wear 1 2 3 2 3 4 45 03...

Page 90: ... tighten the lower lock nut Check the adjustment Tighten the lock nut and check the freeplay again Lower Adjustment The lower clutch cable adjuster is used if the upper clutch cable adjuster is threaded out near its limit or the correct freeplay cannot be obtained Loosen the upper lock nut and turn the upper clutch cable adjuster all the way in to provide maximum freeplay Tighten the upper lock nu...

Page 91: ...u can t get proper adjustment or the clutch does not work properly the cable may be kinked or worn or the clutch discs may be worn See your Honda dealer or refer to the official Honda Service Manual page Check that the clutch lever assembly is positioned properly and the securing bolts are tight Lubricate the clutch cable with a commercially available cable lubricant to prevent premature wear and ...

Page 92: ...n minutes of stop and go riding is sufficient Do not attempt to compensate for faults in other systems by adjusting idle speed See your Honda dealer for regularly scheduled carburetor adjustments Warm up the engine shift to neutral and place the motorcycle on its stand Connect a tachometer following the tachometer manufacturer s instructions Adjust idle speed with the throttle stop screw 1 2 3 1 I...

Page 93: ...proper heat range can cause engine damage Refer to on page Use only the recommended type of spark plugs in the recommended heat range The recommended standard spark plug is satisfactory for most riding conditions However if you plan to ride for extended periods at high speeds or near maximum power high engine rpm in hot climates or plan extended riding in cold climates a different plug may be reco...

Page 94: ...ent cross threading If you have to install a new plug first check the gap Make sure the plug washer is in good condition Check the spark plug gap using a wire type feeler gauge If adjustment is necessary bend the side electrode carefully The gap should be Inspect the spark plug electrodes for wear The center electrode should have square edges The side electrode should not be eroded The insulator s...

Page 95: ...r servicing prevents carbon buildup which can diminish engine performance and also complies with USDA regulations for regular maintenance to assure proper function The spark arrester prevents random sparks from the combustion process in your engine from reaching the environment Allow the engine and muffler to cool Remove the three bolts the spark arrester and the gasket from the muffler 1 2 2 1 3 ...

Page 96: ... screen Be careful to avoid damaging the spark arrester screen The spark arrester must be free of breaks and holes Replace if necessary Check the gasket Replace if necessary Install the spark arrester and the gasket in the muffler and tighten the three bolts securely 3 4 03 05 20 10 09 34 31KCY680_096 ...

Page 97: ... motorcycle If any suspension components appear worn or damaged see your Honda dealer for further inspection Your dealer is qualified to determine whether or not replacement parts or repairs are needed Check fork operation Pull the front brake lever in to lock the brake Then pump up and down on the fork legs several times The suspension should function smoothly There should be no oil leakage 1 45 ...

Page 98: ... Servicing Your Honda Place the motorcycle on a maintenance stand Push hard against the side of the rear wheel and feel for any freeplay which indicates worn swingarm bearings Check the security of all handlebar and fork mounting bolts If any front suspension components appear worn or damaged see your Honda dealer for further inspection cont d 1 1 1 2 03 05 20 10 09 51 31KCY680_098 ...

Page 99: ...hock absorber attachment points and rear suspension linkage attachment points are secure Check for oil leaks in the shock absorber If any rear suspension components appear worn or damaged see your Honda dealer for further inspection 2 3 3 2 03 05 20 10 09 56 31KCY680_099 ...

Page 100: ...the final stages are hard The initial stages of travel are too soft but the final stages are good The initial stages of travel are too hard but the final stages are good softer stiffer stiffer softer increase reduce reduce increase softer stiffer stiffer softer The front suspension can be adjusted for the rider s weight and riding conditions by changing the oil volume and the rebound and compressi...

Page 101: ... Suspension Servicing Your Honda The standard air pressure is 0 psi 0 kPa 0 kgf cm You may relieve accumulated air pressure in the fork legs by using the pressure release screws The front wheel should be off the ground before you release the pressure 2 03 05 20 10 10 15 31KCY680_101 ...

Page 102: ...sion Servicing Your Honda Raise the front wheel off the ground by placing a support block under the engine Remove the pressure release screws Check that the O ring is in good condition Install the pressure release screws cont d 4 3 1 2 1 03 05 20 10 10 25 31KCY680_102 ...

Page 103: ...ey are damaged The fork caps are under extreme spring pressure Use care when removing the caps and wear eye and face protection Compress the fork all the way and measure the oil level from the top of the tubes Standard oil level To prevent fork damage do not fill past the recommended maximum level To prevent poor performance do not use a level lower than the recommended minimum To lower the oil le...

Page 104: ...ith a lint free cloth Install the fork springs Oil the fork cap O rings and install the fork caps Torque the fork caps to The rebound damping adjuster has at least positions Turning the adjuster screw one full turn advances the adjuster positions Rebound Damping Always start with the full hard position when adjusting damping cont d 5 6 12 6 03 05 20 10 10 45 31KCY680_104 ...

Page 105: ...osition Turn the adjuster clockwise until it will no longer turn lightly seats This is the full hard position Make sure that both fork legs are adjusted to the same position Turn the adjuster counterclockwise clicks until the punch mark on the adjuster aligns with the reference mark 1 2 3 1 3 3 2 03 05 20 10 10 52 31KCY680_105 ...

Page 106: ...ssion Damping Compression damping affects how quickly the fork compresses The fork compression damping adjuster has at least positions clicks Turning the adjuster screw one full turn advances the adjuster positions Always start with the full hard position when adjusting damping cont d 4 14 03 05 20 10 11 02 31KCY680_106 ...

Page 107: ...an be adjusted for the rider s weight and riding conditions by changing the spring pre load and the rebound and compression damping Use the following chart to determine the correct adjustment for you The rear shock absorber assembly includes a damper unit that contains high pressure nitrogen gas Do not attempt to disassemble service or dispose of the damper see your Honda dealer The instructions f...

Page 108: ...to a softer position to decrease damping force Excessive Sinking turn the compression adjuster to a stiffer position to increase damping force shorten the spring length to increase pre load increase the spring length to decrease pre load shorten the spring length to increase pre load turn the compression adjuster to a stiffer position to increase damping force Make changes one step at a time Test ...

Page 109: ...ne is cold because it is necessary to remove the muffler An optional pin spanner is available for turning the lock nut and adjusting nut to adjust spring pre load Remove the seat page Remove the right side cover page Remove the muffler by loosening the muffler clamp bolt and removing the lower and upper muffler bolts Pull the muffler away from the exhaust pipe 1 2 3 60 58 3 2 4 03 05 20 10 11 34 3...

Page 110: ...rame upper bolt 9 101 Suspension Servicing Your Honda Loosen the screw on the air cleaner connecting tube clamp and remove the air cleaner connecting tube from the carburetor Be careful not to allow dust into the carburetor Severe engine damage could result Disconnect the electrical connectors cont d 5 5 4 6 03 05 20 10 11 42 31KCY680_110 ...

Page 111: ...2 Suspension Servicing Your Honda Measure the spring length Loosen the rubber band and clip Remove the three subframe mounting bolts Remove the subframe by pulling it straight back Raise the rear wheel off the ground by placing a support block under the engine 1 Standard Minimum Maximum 6 7 8 9 10 8 10 7 9 03 05 20 10 11 52 31KCY680_111 ...

Page 112: ... to shorten the spring length Do not shorten to less than To decrease spring pre load Loosen the lock nut with the optional pin spanner and turn the adjusting nut to increase the spring length Do not increase to more than Each turn of the adjuster changes spring length and spring pre load One turn equals spring length spring pre load Tighten the lock nut and install the removed parts cont d 2 3 2 ...

Page 113: ...ighten the air cleaner connecting tube clamp and the rear brake fluid reservoir stay mount bolt If a torque wrench is not used for installation see your Honda dealer as soon as possible to verify proper assembly Install the muffler and tighten the bolts Be careful not to damage the packing installed inside the muffler clamp Tighten to the specified torque Muffler clamp bolt Muffler bolt lower Muff...

Page 114: ...at least positions Turning the adjuster one full turn advances the adjuster positions To avoid damage to the damping adjuster do not keep it in the full hard position Turn the adjuster clockwise until it will no longer turn lightly seats This is the full hard position Turn the adjuster counterclockwise clicks until the punch mark on the adjuster aligns with the reference mark at the lower end of t...

Page 115: ...mpression damping adjuster has at least positions Turning the adjuster one full turn advances the adjuster positions Turn the adjuster clockwise clicks until the punch mark on the adjuster aligns with the reference mark Turn the adjuster counterclockwise until it will no longer turn lightly seats This is the full soft position 1 2 6 12 14 1 2 3 03 05 20 10 12 35 31KCY680_115 ...

Page 116: ...are no fluid leaks Periodically inspect the brake fluid level and the brake pads for wear If the front brake lever or rear brake pedal freeplay does not feel within the normal range while riding check the brake pads If they are not worn beyond the recommended limit page there is probably air in the brake system See your Honda dealer to have the air bled from the system Never use adjusters other th...

Page 117: ...ock nut To position the brake lever farther away from the handgrip turn the adjuster clockwise To position the brake lever closer to the handgrip turn the adjuster counterclockwise Tighten the lock nut Apply the brake release it then spin the wheel and check that it rotates freely Repeat this procedure several times Check freeplay by pulling in slowly on the front brake lever until the brake start...

Page 118: ...n an upright position check the fluid level It should be between the UPPER and LOWER level mark If the level is at or below the LOWER level mark check the brake pads for wear page Check for deterioration or cracks in the hoses and fittings Make sure there are no fluid leaks Other Inspections Worn brake pads should be replaced If the pads are not worn have your brake system inspected for leaks The ...

Page 119: ...d riding area conditions Generally the pads will wear faster on wet and dirty riding terrain Inspect the pads at each regular maintenance interval page Check that the front lever and rear pedal assemblies are positioned properly and the securing bolts are tight Check the cutout in each pad If either pad is worn to the cutout replace both pads as a set See your Honda dealer for this service 2 50 03...

Page 120: ...onda Brake fluid should be added and replaced by your Honda dealer The recommended brake fluid is Honda DOT 4 Brake Fluid or any brake fluid of equal equality and performance Use fresh brake fluid from a sealed container 03 05 20 10 13 24 31KCY680_120 ...

Page 121: ...nitial seating of the parts Excessively loose spokes may result in instability at high speeds and the possible loss of control It s also important that the rim locks are secure to prevent tire slippage It is not necessary to remove the wheels to perform the recommended service in the Maintenance Schedule However information for wheel removal is provided for emergency situations Inspect the wheel r...

Page 122: ...nce stand or support block under the engine Secure the rear of the motorcycle with tie down straps Remove the front axle holder nuts and the front axle holder Unscrew and remove the axle Remove the wheel Avoid depressing the brake lever and brake pedal when the wheel is off the motorcycle This will force the caliper pistons out of the cylinders The result will be loss of brake fluid If this occurs...

Page 123: ...everal times and then check if the wheel rotates freely Recheck the wheel if the brake drags or if the wheel does not rotate freely Check front brake adjustment page If a torque wrench was not used to install the wheel see your Honda dealer as soon as possible to verify proper assembly Improper assembly may lead to loss of braking capacity Reverse the removal procedure Insert the axle through the ...

Page 124: ... 2 2 RIGHT REAR LEFT REAR 1 rear axle nut 2 adjuster 1 2 adjuster 3 rear axle 3 115 Rear Wheel Removal Wheels Servicing Your Honda cont d 03 05 20 10 14 04 31KCY680_124 ...

Page 125: ...maximum drive chain slack Move the rear wheel forward Derail the drive chain from the driven sprocket Move the rear axle back all the way to the swingarm end Pull down on the rear axle Avoid depressing the brake lever and brake pedal when the wheel is off the motorcycle This will force the caliper pistons out of the cylinders The result will be loss of brake fluid If this occurs the brake system w...

Page 126: ...otates freely Repeat this procedure several times If a torque wrench was not used to install the wheel see your Honda dealer as soon as possible to verify proper assembly Improper assembly may lead to loss of braking capacity Reverse the removal procedure Make sure the lug on the brake caliper is located in the slot in the swing arm Check that the chain adjusters are installed properly 1 2 3 4 4 5...

Page 127: ...detailed information on how and when to check your air pressure how to inspect your tires for wear and damage and our recommendations on tire repair and replacement Make sure the valve stem caps are secure If necessary install a new cap Properly inflated tires provide the best combination of handling tread life and riding comfort Generally underinflated tires wear unevenly adversely affect handlin...

Page 128: ...r a few miles the readings will be higher If you let air out of warm tires to match the recommended cold pressures the tires will be underinflated The correct cold tire pressures are A flat tire or blowout is inconvenient and may even cause an accident Take time to inspect your tires and wheels before you ride For more information about handling flat tires see page If you decide to adjust tire pre...

Page 129: ...d carefully inspect the tire as described on page Inspect carefully for bumps or bulges in the side of the tire or the tread Replace any tire that has a bump or bulge Look closely for cuts slits or cracks in the tires Replace a tire if you can see fabric or cord Check for rocks or other objects embedded in the tire or tread Remove any objects Check the position of both valve stems A tilted valve s...

Page 130: ...vicing Your Honda The tires that came on your motorcycle were designed to provide a good combination of handling braking durability and comfort across a broad range of riding conditions Use a replacement tire equivalent to the original Replace the tube any time you replace a tire The old tube will probably be stretched and if installed in a new tire could fail Have the wheel balanced after a new t...

Page 131: ...ions Refer to on page Check the side stand spring for damage and loss of tension Check the side stand assembly for freedom of movement If the side stand is stiff or squeaky clean the pivot area and lubricate the pivot bolt with clean engine oil 1 2 1 45 03 05 20 10 15 12 31KCY680_131 ...

Page 132: ...motorcycle is ridden in unusually dusty or muddy areas more frequent maintenance will be necessary Before servicing your drive chain turn the engine OFF lower the side stand and check that your transmission is in neutral It is not necessary to remove or replace the drive chain to perform the recommended service in the Maintenance Schedule Check slack in the lower drive chain run midway between the...

Page 133: ...s Replace the drive chain page if it has damaged rollers loose pins or kinks that cannot be freed Lubricate the drive chain page if it appears dry or shows signs of rust Lubricate any kinked or binding links and work them free Adjust chain slack if needed Check the chain slipper chain guide slider and chain roller for wear If the depth of the groove in the chain slipper exceeds the depth limit hav...

Page 134: ...xcessive when the rear axle is moved to the farthest limit of adjustment Excessive slack indicates the chain is worn beyond its service limit To check the chain s service limit remove the drive chain page Then measure the distance between a span of pins from pin center to pin center If the distance exceeds the service limit the drive chain is worn out and should be replaced cont d 5 New Chain Serv...

Page 135: ... Sprocket Teeth GOOD REPLACE LEFT SIDE 2 RIGHT REAR 126 Adjustment Drive Chain Servicing Your Honda Use of a new chain with worn sprockets will cause rapid chain wear Inspect the front and rear sprocket teeth for excessive wear or damage If necessary have your Honda dealer replace a worn sprocket 6 03 05 20 10 15 50 31KCY680_135 ...

Page 136: ...Turn both the right and left adjusters equally to increase or decrease chain slack After adjusting be sure the same adjuster index marks align with the stopper pins on both sides of the swingarm Turn the axle end bar to the lower edge of the swing arm Torque the rear axle nut to If a torque wrench is not used for this installation see your Honda dealer as soon as possible to verify proper assembly...

Page 137: ...loose fitting links or otherwise appears unserviceable Remove the master link retaining clip with pliers Do not bend or twist the clip Remove the master link and O rings Remove the drive chain Clean the side surfaces of the chain with a dry cloth Do not brush the rubber O rings Brushing will damage them Use of a solvent may also damage the O rings Replacement chain Lubricate only with SAE 80 or 90...

Page 138: ...ts Inspect the sprocket teeth for wear or damage We recommend replacing the sprocket whenever a new chain is installed Lubricate the drive chain Pass the chain over the sprockets and join the ends of the chain with the master link Master links with O rings have four O rings fitted between the rollers and master link plates For ease of assembly hold the chain ends against adjacent rear sprocket tee...

Page 139: ...tions Refer to on page Disengage the socket from the headlight case Remove the bulb from the socket Remove the two headlight mount bands and remove the front number plate Install a new bulb aligning the tab on the bulb with the groove on the headlight case To install the headlight reverse the removal procedure 1 2 4 4 3 45 3 5 2 1 03 05 20 10 16 34 31KCY680_139 ...

Page 140: ...crew 131 Headlight Aim Headlight Taillight Servicing Your Honda The headlight beam can be raised or lowered Turn the adjusting screw to move the headlight up or down to the proper adjustment 5 03 05 20 10 16 40 31KCY680_140 ...

Page 141: ...ens 3 bulb 3 LEFT REAR 1 2 132 Taillight Bulb Headlight Taillight Servicing Your Honda Remove the two screws Pull the lens off Replace the bulb with a new one Reinstall the lens 2 1 3 1 3 03 05 20 10 16 48 31KCY680_141 ...

Page 142: ...ou re cleaning be sure to look for damage wear and gasoline or oil leaks To clean your motorcycle you may use water a mild neutral detergent and water a mild spray and wipe cleaner polisher a mild spray and rinse cleaner degreaser and water Avoid products that contain harsh detergents or chemical solvents that could damage the metal paint and plastic on your motorcycle If your motorcycle is still ...

Page 143: ...as dish washing liquid or a product made especially for washing motorcycles or automobiles We recommend the use of a garden hose to wash your motorcycle High pressure washers like those at coin operated car washes can damage certain parts of your motorcycle If you use a high pressure washer avoid spraying the following areas wheel hubs muffler outlet area under seat engine stop button brake master...

Page 144: ...Dry your motorcycle with a chamois or a soft towel Lubricate the drive chain to prevent rusting Start the engine and let it idle for several minutes The engine heat will help dry moist areas As a precaution ride at a slow speed and apply the brakes several times This will help dry the brakes and restore normal braking performance The exhaust pipe is stainless steel but may become stained by oil or...

Page 145: ...136 Servicing Your Honda 03 05 20 10 17 23 31KCY680_145 ...

Page 146: ...for an off road adventure how to transport and store your Honda and how to be an environmentally responsible motorcycle owner Preparing for a Ride 138 Transporting Your Honda 140 Storing Your Honda 142 You the Environment 145 03 05 20 10 17 27 31KCY680_146 ...

Page 147: ...d Management USA only the Ministry of Natural Resources Canada only riding clubs and off road magazines are good sources of information We recommend that you always take water food a first aid kit and your owner s manual Other items you should consider loading on your truck or trailer include a tool kit tire repair supplies and tools tubes and tires extra parts such as a drive chain and master lin...

Page 148: ...ends on the kind of terrain how long you expect to ride how far you might go from your base camp or help and how experienced you or your companions are in making repairs If you decide to take some tools spare parts or other supplies on the trail be sure you can carry them safely and know how to use them Also be sure to follow the loading guidelines and weight limit page 6 03 05 20 10 17 43 31KCY68...

Page 149: ...railer rail Attach the lower ends of two straps to the tie down hooks on your vehicle Attach the upper ends of the straps to the handlebar one on the right side the other on the left close to the fork Use a loading ramp Make sure the fuel valve is off Secure the motorcycle in an upright position using motorcycle tie down straps Avoid using rope which can loosen and allow the motorcycle to fall ove...

Page 150: ...ront suspension is compressed about half way Too much pressure is unnecessary and could damage the fork seals Use another tie down strap to keep the rear of the motorcycle from moving We recommend that you do not transport your motorcycle on its side This can damage the motorcycle and leaking gasoline could be a hazard 03 05 20 10 17 56 31KCY680_150 ...

Page 151: ...toring it That way needed repairs won t be forgotten and it will be easier to get your motorcycle running again For more information about storage refer to the available from your Honda dealer USA only We suggest you perform the following procedures to keep your motorcycle in top condition These storage procedures will reduce the deterioration that can occur during storage 03 05 20 10 18 01 31KCY6...

Page 152: ...Storage Drain the carburetor into an approved gasoline container and dispose of it in an approved manner page If storage will last longer than one month carburetor draining is important to assure proper performance after storage Change the engine oil and filter page Fill the fuel tank Make sure the fuel fill cap is properly installed Check that the fuel valve is OFF Wash and dry your motorcycle co...

Page 153: ...Avoid using plastic or similar non breathing coated materials that restrict air flow and allow heat and moisture to accumulate Uncover and clean your motorcycle If your motorcycle has been stored for more than two months drain and replace the fuel If your motorcycle has been stored for more than four months change the engine oil page Lubricate the drive chain Perform a pre ride inspection page the...

Page 154: ... damaged and ride only in areas approved for off road vehicles Loud motorcycles can be offensive Ride as quietly as possible don t remove your spark arrester and don t modify the muffler or any other part of your air intake and exhaust systems Such modifications not only increase noise they also reduce engine performance and may be illegal Use a biodegradeable detergent when you wash your motorcyc...

Page 155: ...d contaminate our drinking water lakes rivers and oceans Before changing your oil make sure you have the proper containers Put oil and other toxic wastes in separate sealed containers and take them to a recycling center Call your local or state office of public works or environmental services to find a recycling center in your area and get instructions on how to dispose of non recyclable wastes 03...

Page 156: ... sometime something may go wrong This section gives practical advice to help you deal with a wide range of problems Take time to read this section before you ride Also review the tips in page General Guidelines 148 If Your Engine Quits or Won t Start 149 If You Have a Flat Tire 150 If You Crash 151 If a Component Fails 152 138 03 05 20 10 18 38 31KCY680_156 ...

Page 157: ... decide what to do Whatever the problem the most important rules are If a problem is relatively minor and you have the tools supplies and skills to make a permanent repair you may be able to fix it on the trail and continue riding Or you may be able to make a temporary repair that allows you to slowly ride back to your base where you can make a permanent repair or get help When a problem is more s...

Page 158: ...king any unusual noises before it quit running and it feels normal when you operate the kickstarter you can probably rule out a major mechanical problem Make sure there is enough gas in the tank and the fuel valve is at the ON or RESERVE position Check the fuel fill cap vent tube to see if it is pinched or obstructed Turn the fuel valve OFF disconnect the fuel line that goes from the fuel valve to...

Page 159: ... if you have one with you If there is still no spark there is a problem in the ignition system If you cannot identify or correct the problem you will have to push your motorcycle back to your base or get some help How you handle a flat tire on the trail depends on how serious the tube or tire damage is and what tools and supplies you have with you If you have a slow leak or a minor puncture there ...

Page 160: ...e The motorcycle will be hard to handle and if the tire comes off the rim it may lock up the wheel and cause you to crash Personal safety is your first priority after an accident If you or anyone else has been injured take time to assess the severity of the injuries and whether it is safe to continue riding If you cannot ride safely send someone for help Do not ride if you will risk further injury...

Page 161: ...Honda dealer check the frame and suspension after any serious crash The drive chain master link brake lever or pedal control cables and other components can be damaged as you ride in dense brush or over rocky terrain Making a trailside repair depends on how serious the damage is and what tools and supplies you have with you If the drive chain comes off because the master link clip gets knocked off...

Page 162: ...tch lever breaks you may be able to temporarily switch the front brake lever to the clutch side then ride carefully back to base using the rear brake for slowing or stopping If you damage a throttle cable or other critical component your motorcycle may be unsafe to ride Carefully assess the damage and make any repairs that you can But if there is any doubt it s best to be conservative and safe 03 ...

Page 163: ...154 Taking Care of the Unexpected 03 05 20 10 19 31 31KCY680_163 ...

Page 164: ...nd other technical data plus information on government requirements and how to break in your motorcycle Vehicle Identification 156 Specifications 158 Break in Guidelines 163 High Altitude Carburetor Adjustment 164 Emission Control Systems 165 Oxygenated Fuels 169 03 05 20 10 19 35 31KCY680_164 ...

Page 165: ...d engine serial numbers are required when you register your motorcycle They may also be required when ordering replacement parts You may record these numbers in the section at the rear of the manual The frame number is stamped on the right side of the steering head The engine number is stamped on the left crankcase 1 2 03 05 20 10 19 44 31KCY680_165 ...

Page 166: ...l Information Quick Reference The color label is attached to the frame behind the left side cover page The color code is helpful when ordering replacement parts You may record the color and code in the section at the rear of the manual 1 58 03 05 20 10 19 51 31KCY680_166 ...

Page 167: ...51 US gal 9 5 0 40 US gal 1 5 1 8 US qt 1 7 2 3 US qt 2 2 1 9 US qt 1 8 unleaded gasoline pump octane number of 91 or higher Overall length Overall width Overall height Wheelbase Dry weight Fuel tank capacity Fuel tank reserve Fuel recommendation Engine oil capacity Dimensions Weight Fuel Lubricants 158 Specifications Technical Information 03 05 20 10 20 05 31KCY680_167 ...

Page 168: ...d MA Pro Honda GN4 or HP4 without molybdenum additives 4 stroke oil USA Canada or Honda 4 stroke oil Canada only or an equivalent motorcycle oil 3 3 2 8 in 85 70 mm 18 9 US oz 559 cm Displacement Bore stroke Compression ratio Passenger capacity Maximum weight capacity Cargo capacity Fork oil capacity each side Air cleaner oil Engine oil recommendation Drive chain lubricant Fuel Lubricants Engine S...

Page 169: ... NGK X27GPR U DENSO 0 024 0 028 in 0 60 0 70 mm 1 300 100 rpm or Intake Exhaust or or Primary reduction Gear ratio 1st 2nd 3rd 4th 5th Final reduction Standard sprocket sizes Final drive Valve clearance cold Spark plug standard Spark plug extended high speed riding Spark plug gap Idle speed Engine Specifications Power Transmission 160 Specifications Technical Information 03 05 20 10 20 33 31KCY680...

Page 170: ... 1 0 kgf cm 15 psi 100 kPa 1 0 kgf cm 11 0 in 280 mm 11 8 in 300 mm axle travel cushion stroke Drive chain freeplay New chain length Used chain service limit length Caster Trail Tire size front Tire size rear Tire pressure front cold Tire pressure rear cold Suspension front Suspension rear Power Transmission Chassis Suspension 161 Specifications Technical Information 03 05 20 10 20 46 31KCY680_170...

Page 171: ...bf ft 25 N m 2 5 kgf m 16 lbf ft 22 N m 2 2 kgf m 65 lbf ft 88 N m 9 0 kgf m Alternator Headlight Taillight Fork caps Crankcase drain bolt Frame drain bolt Oil filter bolt Rear wheel axle Front wheel axle Front wheel axle holder nuts Electrical Lights Torque Specifications 162 Specifications Technical Information 03 05 20 10 20 57 31KCY680_171 ...

Page 172: ... assure your motorcycle s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles 25 km During this period avoid full throttle starts and rapid acceleration 03 05 20 10 21 01 31KCY680_172 ...

Page 173: ...le at high altitude the air fuel mixture becomes overly rich Above 6 500 feet 2 000 m driveability and performance may be reduced and fuel consumption increased The carburetor can be modified to compensate for this high altitude richness However the carburetor must be returned to standard factory specifications when lower altitude riding is desired See your Honda dealer for high altitude modificat...

Page 174: ...its useful life when operated and maintained according to the instructions provided California only The EPA also requires that motorcycles built after January 1 1983 comply with applicable noise emission standards for one year or 1 865 miles 3 000 km after the time of sale to the ultimate purchaser when operated and maintained according to the instructions provided USA only The Vehicle Emission Co...

Page 175: ... The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere Blow by gas is returned to the combustion chamber through the air cleaner and the carburetor The combustion process produces carbon monoxide CO and hydrocarbons HC Control of hydrocarbons is very important because under certain conditions they react to form photochemical smog when ...

Page 176: ...ntrol prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Removal of or puncturing the muffler baffles header pipes or any other component which conducts exhaust gases Removal of or puncturing of any part of the intake system Lack of proper maintenance...

Page 177: ...f any of the following symptoms have the vehicle inspected and repaired by your Honda Motorcycle Dealer Hard starting or stalling after starting Rough idle Misfiring or backfiring during acceleration After burning backfiring Poor performance driveability and poor fuel economy 1 2 3 4 5 03 05 20 10 21 28 31KCY680_177 ...

Page 178: ...imum octane rating requirement Before using an oxygenated fuel try to confirm the fuel s contents Some states provinces require this information to be posted on the pump The following are the EPA approved percentages of oxygenates MTBE Methyl Tertiary Butyl Ether 15 by Volume You may use gasoline containing up to 15 MTBE by volume METHANOL methyl or wood alcohol 5 by Volume You may use gasoline co...

Page 179: ...her service station or switch to another brand of gasoline Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under warranty Oxygenated fuels can damage paint and plastic Be careful not to spill fuel when filling the fuel tank Wipe up any spills immediately 03 05 20 10 21 42 31KC...

Page 180: ...contains information on your warranty and how to get an official Honda service manual Authorized Manuals 172 Warranty Coverage 175 Warranty Service 176 Contacting Honda 177 The Honda Rider s Club USA only 178 Your Honda Dealer 179 03 05 20 10 21 47 31KCY680_180 ...

Page 181: ...anada See your Honda dealer to order authorized manuals Also available but not necessary to service your model is the Honda Common Service Manual Publication No which explains theory of operation and basic service information for various systems common to all Honda motorcycles motor scooters and ATVs These Honda manuals are written for the professional technician but most mechanically capable owne...

Page 182: ...and Total 4 00 173 Order On Line www helminc com Order Toll Free 1 888 CYCLE93 OR Consumer Information NOTE For Credit Card Orders Only 1 888 292 5393 Monday Friday 8 00 AM 6 00 PM EST By completing this form you can order the materials desired You can pay by check or money order or charge to your credit card Mail to Helm Inc at the address shown on the back of this order form USA only Canada See ...

Page 183: ...ications cannot be returned for credit without receiving advance authorization within 14 days of delivery On returns a restocking fee may be applied against the original order Check here if your billing address is different from the shipping address shown above Expiration Mo Yr Account Number Check or money order enclosed payable to Helm Inc U S funds only Do not send cash P O BOX 07280 DETROIT MI...

Page 184: ...ion Plan USA only For more information see your Honda dealer There are responsibilities restrictions and exclusions which apply to these warranties Please read the Honda Motorcycle Warranties Booklet given to you by your Honda dealer at the time of purchase Be sure to keep your Honda owner s card USA only with your Warranties Booklet Motorcycle Limited Warranty Noise Control Warranty USA only It i...

Page 185: ...results of the inspection If the problem is covered under warranty your dealer will perform the warranty repairs for you If you have questions about warranty coverage or the nature of the repair it is best to talk to the service manager of your Honda dealer Sometimes in spite of the best intentions of all concerned a misunderstanding may occur If you aren t satisfied with your dealer s handling of...

Page 186: ...nces at the dealership level If you wish to comment on your experiences with your Honda or with your dealer please send your comments to the following address USA only Motorcycle Division American Honda Motor Co Inc P O Box 2220 Torrance CA 90509 2220 mailstop 100 4W 5B telephone 310 532 9811 Canada Refer to the warranty booklet that was supplied with your vehicle Please include the following info...

Page 187: ...going again Reimbursement to 75 for motorcycle and scooter rider training from the Motorcycle Safety Foundation Free ATV rider training is available from the Specialty Vehicle Institute of America with the purchase of a new Honda ATV A subscription to a bi monthly insider s magazine for all members Special members only HRCA website Discounts from HRCA partners for both on and off road riding schoo...

Page 188: ...ada only The same quality that went into your Honda can be found in Genuine Honda replacement parts You ll also find comparable quality in the accessories and products available from the parts department The sales department offers the Honda Protection Plan to extend almost all of your warranty coverage USA only Your dealer can inform you about competition and other riding events in your area You ...

Page 189: ...fications 5 Loading 5 Accessories Modifications 7 Safety Labels 9 Component Locations 12 Fuel Valve 15 Choke Lever 16 Engine Stop Button 17 Front Brake Lever 17 Throttle 17 Clutch Lever 17 Shift Lever 18 Rear Brake Pedal 18 Kickstarter 18 Starter Decompressor Lever 18 Side Stand 19 Tripmeter 19 Are You Ready to Ride 22 Protective Apparel 22 Is Your Motorcycle Ready to Ride 24 Pre ride Inspection 2...

Page 190: ...tarter Decompressor Lever 32 Flooded Engine 33 How to Stop the Engine 34 Shifting Gears 35 Braking 37 Parking 39 Post ride Inspection 40 The Importance of Maintenance 43 Maintenance Safety 45 Important Safety Precautions 45 Maintenance Schedule 47 Maintenance Record 51 Competition Inspection 52 Component Locations 55 Tools 57 Side Cover Removal 58 Air Cleaner Housing Cover Removal 59 Seat Removal ...

Page 191: ...lifornia only 76 Engine Throttle 77 Clutch System 80 Engine Idle Speed 83 Spark Plug 84 Spark Arrester 86 Chassis Suspension 88 Brakes 107 Wheels 112 Tires Tubes 118 Side Stand 122 Drive Chain 123 Headlight Taillight 130 Appearance Care 133 Preparing for a Ride 138 Transporting Your Honda 140 Storing Your Honda 142 You the Environment 145 03 05 20 10 23 15 31KCY680_191 ...

Page 192: ...rranty Service 176 Contacting Honda 177 The Honda Rider s Club USA only 178 Your Honda Dealer 179 General Guidelines 148 If Your Engine Quits or Won t Start 149 If You Have a Flat Tire 150 If You Crash 151 If a Component Fails 152 Vehicle Identification 156 Specifications 158 Break in Guidelines 163 High Altitude Carburetor Adjustment 164 Emission Control Systems 165 Oxygenated Fuels 169 03 05 20 ...

Page 193: ...n 92 tires 118 altering your motorcycle 8 arrester spark 86 Authorized Manuals 172 capacity fuel 62 carburetor high altitude adjustment 164 idle speed 83 choke lever 16 cleaner air 73 cleaning appearance care 133 clutch system adjustment 80 lever 17 color label 157 competition inspection 52 consumer information 171 controls operating 11 cover removal side 58 crankcase breather California only 76 0...

Page 194: ... speed 83 pinging 61 starting 29 stop button 17 stopping 34 won t start 149 environment protecting 145 exhaust pipe maintenance 135 filter air 73 oil 68 flat tire 150 flooded engine starting 33 fork 88 91 frame number 156 front brake lever freeplay 107 front suspension maintenance 88 front wheel removal 113 fuel recommendation 61 oxygenated 169 tank capacity 62 valve 15 03 05 20 10 23 32 31KCY680_...

Page 195: ...onda service manual 172 lever clutch 17 front brake 17 shift 18 starter decompressor 18 32 limit weight 6 loading 5 idle speed engine 83 inspection competition 52 post ride 40 pre ride 24 gap spark plug 85 gasohol 169 gasoline 61 gears shifting 35 03 05 20 10 23 40 31KCY680_195 ...

Page 196: ... fork 93 operating controls 11 oxygenated fuels 169 pad brake 110 parking 39 pedal rear brake 18 pinging engine 61 plug spark 84 post ride inspection 40 pre ride inspection 24 pre load rear suspension 100 rear suspension maintenance 89 reserve capacity fuel tank 62 rider training 3 179 cont d 03 05 20 10 23 48 31KCY680_196 ...

Page 197: ...ranty 176 manuals 172 shifting gears 35 side cover removal 58 side stand 19 122 spark arrester 86 spark knock 61 spark plug 84 specifications 158 spring pre load rear suspension 100 stand side 19 122 starter decompressor lever 18 32 starting engine 29 stop button engine 17 stopping engine 34 storage 142 suspension front 88 91 rear 89 98 03 05 20 10 23 53 31KCY680_197 ...

Page 198: ...175 extended 175 service 176 washing your motorcycle 134 weight limit 6 wheels 112 taillight 132 throttle freeplay 77 operation 17 tires air pressure 118 flat 150 replacing 121 tool bag 57 towing 36 training rider 3 179 transporting 140 tripmeter 19 troubleshooting starting 149 03 05 20 10 24 00 31KCY680_198 ...

Page 199: ...rd important notes The engine of your Honda can be the most expensive component to repair Proper maintenance especially the use of the recommended fluids and filters prevents premature wear and damage Frequent causes of costly engine repairs are Engine oil insufficient quantity improper oil Air cleaner dirty leaking because of improper installation poor seal 03 05 20 10 24 07 31KCY680_199 ...

Page 200: ...eference Quick Reference Record important information here Frame No Engine No Color Label Owner s Name Address City State Phone Dealer s Name Address City State Phone Service Mgr 03 05 20 10 24 11 31KCY680_200 ...

Page 201: ... throttle brakes clutch lever headlight Initial Maintenance Pre ride Inspection Fuel Capacity Engine Oil Regular Maintenance unleaded gasoline pump octane number of 92 or higher tank reserve rider only no passenger or cargo and any accessories Tires Maximum Weight Capacity API Service Classification SG or higher except oils labeled as energy conserving on the circular API service label SAE 20W 50 ...

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Honda 2004 XR400R, Owner'S Manual

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