______________________________________________ Thank you for purchasing a Honda motorcycle. For your safety and comfort, please familiarise yourself with this manual before riding. 0 At time of purchase Motorcycle rider’s license * This motorcycle has a total displacement of 397cm³(cc). You must hold a corresponding motorcycle rider’s license in order to ride on public roads.     Ask your dealer for the following: Tips on handling and riding. Conditions/period of the warranty. Service requirements Filling out the purchase receipt and ensuring your new Honda is registered for warranty card. The vehicle is designed to carry a maximum of two people, including the rider. Note that you cannot carry a passenger for the first 12 months after obtaining your motorcycle license. 1 Safety Warnings _____________________________________________ About this manual Safety warnings * This manual contains information for the correct handling, safe riding and basic maintenance of your motorcycle. Please read through “Safety Warning”, “Safe riding” and “Maintenance safety tips” as they are particularly important. * Even if you are familiar with motorcycles already, please read this manual as this model has some special features. Please also read the maintenance notes. * When re-selling the vehicle please hand this manual and the maintenance record to the next owner. * Honda MPE reserves the right to alter specifications and make other changes at any time without notice or obligation. * Safety warnings The following safety warnings are used in this manual to alert you to the potential for danger to the rider, the passenger and others. Always read the warnings thoroughly. Warning: High potential of causing death or severe injury. Caution: Potential of causing death or severe injury. Note: Potential of minor injury. * Other symbols: Advice: In order to maintain the motorcycle in the best condition. Tips: Some useful information. 2 Contents _____________________________________________ SAFETY WARNINGS………………………… CONTENTS……………………………………. FOR YOUR OWN SAFETY………………...... Before Riding…………………………………... Protective Apparel……………………………... Riding Tips……………………………………... Luggage & Modifications……………………… Parking………………………………………….. PARTS LOCATION…………………………… INSTRUMENTS AND INDICATORS……….. Instruments…………………………………. Speedometer……………………………….. Odometer……………………………….…... Trip meter…………………………………… Indicators / Warning Lamps…………….. Turn signal indicator……………………….. High beam pilot lamp………………….…... Neutral indicator……………………………. Switches…….………………………….. Ignition switch………………………………. Head lamp dimmer switch…...………….... Engine stop switch…………………………. Starter button………………………………. Horn button…………………………………. 1 2 4 4 6 7 8 9 10 12 12 12 12 12 13 13 13 13 14 14 15 16 17 17 Turn signal switch…………………………. Features / Accessories.……..………….. Steering lock…………………………….. Helmet holder……………………………… Document bag………………………….…. Tool kit holder……………………………… 18 19 19 20 21 21 Fuel Supply……..……………………… Refuelling………………………………………. Fuel cock…………………………………… 22 22 23 Basic Operation……….………………... Starting the engine…………….……….…. Changing gear…………………..………… Riding tips………………………..………… Braking……………………………..….…… 24 24 27 28 30 3 Contents _____________________________________________ MAINTENANCE SAFETY TIPS…………….. Maintenance………………………………….. Daily inspection……………………………. Regular service……………………………. Maintenance Schedule 32 35 37 40 41 Basic maintenance…………………...….….. Engine oil………………………………… Oil level check………………….……….. Adding Oil…………………..……… Oil quantity check………………………. Drive Chain……………………………… Drive Chain Lubrication / Cleaning 44 45 45 46 48 50 51 Brakes / Clutch …..……………………. Brake fluid level…………………………. Brake pad wear / inspection ………...... Clutch lever free play…………………… Clutch - free play adjustment…………… 52 52 53 54 55 Battery ..……………………….. Battery Terminals………………….… Battery removal / installation……….…… Fuses…………..………………………….. Inspection / replacement………………… Tyres………….....…………………………….. Pressure…………………………………… Tread……………….………..…………….. Replacement tyres…………..…………… Air Filter…………….……………..………….. Air filter element replacement..…………. Cleaning……………………………………….. Damper Unit…………………………………… For our environment…………………….. Colour label…………………………... Genuine Honda mufflers………………... Frame serial number (VIN)………………. Troubleshooting…………………. Crankcase breather cleaning Specifications………...……………….. Noise Warning…………… 4 56 57 58 59 59 61 61 61 62 63 63 64 66 66 67 68 69 70 70 71 74 For Your Own Safety _______________________________________________  Before Riding The topics described here are the basic instructions for handling the vehicle. Please follow the instructions from your owner’s manual.    Please conduct the daily inspection. Keep the vehicle clean at all times and inspect the specified items. Refer to p. 37 for details. Please conduct the regular service. Refer to p.40 for details. 5 For Your Own Safety _____________________________________________  Please stop the engine and keep clear of fire when refueling.  Exhaust gas is toxic. Operate the engine in a well ventilated place. 6 For Your Own Safety _____________________________________________ Protective apparel  Both rider and passenger are required by law to wear a helmet. Secure the strap properly. Helmets approved to AS1698 are the only legal helmets in Australia.  Wear protective clothing and gear such as:  Face shield or goggles.  Motorcycle boots or any footwear that covers the ankles.  Leather gloves.  Long pants and a long sleeved jacket. Riding apparel should be bright or reflective. Allow freedom of movement. Avoid flared pants and loose sleeved jackets, which could get caught with the brake and gear shift pedals. Caution Wearing the helmet incorrectly increases the risk of serious injury or death in an accident. Both rider and passenger must wear helmets, protective gear and protective clothing. 7 For Your Own Safety _______________________________________________ Riding Tips  Keep both hands on the handlebars and both feet on the foot rests at all times whilst in motion.  The passenger should place both feet on the rear foot rests and use both hands to stay in position. It is the rider’s responsibility to check that the passenger is positioned correctly.  Do not jerk the handlebars or attempt to ride with only one hand. This safety rule applies to any two-wheeled vehicle. 8 For Your Own Safety _______________________________________________ Luggage Modification  Controllability and stability of the vehicle changes by loading luggage. Be careful in terms of loading and securing the luggage. Any modification which affects the function and the structure of the vehicle may affect the controllability and exhaust noise, which may affect the durability of the motorcycle.  Do not place any items around the steering handle. It may obstruct the steering.  Do not place any items in front of the headlamp. It may melt the lens or damage the item itself. Any illegal modification may cause damage to the motorcycle. Any damage caused by these modifications is totally out of our warranty. 9 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. Parking with the sidestand   Notes Do not touch the muffler or the engine while the engine is running or immediately after shutdown. Park the motorcycle so that the engine and the muffler can be kept away from other people.  Park on flat and stable ground with the handlebars turned fully to the left. The vehicle may have difficulty staying upright in the following circumstances:  The handlebars turned to the right.  Parked on sloping, soft, sandy or bumpy ground. If there is no other choice, take maximum precautions to keep the vehicle stable. 10 Parts Location _______________________________________________ 11 Parts Location _____________________________________________ 12 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. Reset to zero by rotating the reset knob in the direction of the arrow as shown. 13 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. 14 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 left “ON” without the engine running. Tips Lock the Steering and pull the key out whenever you leave the vehicle. Key position ON OFF LOCK 15 Function Start, day/night ops  Headlamp “ON”  Able to use turn signals, horns, and stops lamps. Stop  All electrical systems disabled Steering lock engaged  All electrical systems disabled Remove Key Unable Yes Yes 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. 16 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. It may also damage the engine. Advice If using this switch in an emergency, stop the engine and turn the ignition switch OFF to avoid battery becoming flat. 17 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.   Tip The starter motor cannot be engaged if the engine stop switch is OFF. The headlamp turns OFF when the starter motor is engaged. Horn Button The horn sounds by pushing the horn switch when the ignition switch is ON. 18 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 < OFF > RIGHT). Push in to cancel.   Tip The turn signal does not cancel automatically. Always cancel the switch after turning to avoid confusing other drivers. Use a bulb with the correct wattage. The turn signal lamp will not operate correctly if the wattage is not correct. 19 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. Insert the key into the ignition switch. 3. Push the key in and turn it to “Lock” position. 4. Remove the key. To disengage the lock Follow the above procedure in reverse order. Tip Always Park in a safe place away from traffic. Jiggle the handlebar to check the lock is engaged. 20 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. Unlock the Helmet Holder Lock 2. Pass the helmet holder wire through the ring on the helmet strap and hook to the helmet holder. 3. Lock the Helmet Holder Lock Keep the helmet holder wire in storage when the holder is not in use. Advice Do not move the motorcycle with the helmet attached as it may damage the helmet surface. 21 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. Tip When washing the motorcycle, do not apply water directly to the Tool Kit Holder as it may enter and damage Tools/Documents. 22 Fuel System _______________________________________________ The XR400M uses only unleaded petrol. Always stop the engine before refueling and keep well clear of naked flames, sparks or heat sources. Refueling 1. Lift up the key cover. Insert the ignition key and turn to the right to open the fuel fill cap. Caution Petrol is highly flammable. Improper handling will result in severe injury. When handling the petrol:  Always stop the engine and keep away from flames, sparks or heat sources.  Refuel outside.  Wipe off spilled petrol straight away.  Do not fill above Fuel Level Plate. 23 Fuel System ______________________________________________ 2. Do not fill higher than the bottom of the filler neck (see diagram) or petrol may seep out through the breather hole on the fuel tank cap. 3. Close the cap firmly and remove the key. The key cannot be removed unless the cap is properly locked. Fuel Cock The fuel cock lever has three positions: “ON” fuel supplied to carburettor when the engine starts. “OFF” select when the motorcycle is not in use for a long period or being serviced. “RES” reserve fuel tank (holds approx 2 litres of fuel) is selected. Turn to RES when you run out of fuel in ON position whilst riding. Refuel as soon as possible and turn back to ON to prevent complete fuel starvation. 24 Basic Operation ______________________________________________ Starting the Engine Engine exhaust fumes contain carbon monoxide and other harmful substances. Always start the engine in well ventilated area. Refer to pages. 24 ~ 26 for the starting procedure.    Advice If the engine fails to start within 5 sec of cranking, release the starter switch for 10 sec before another attempt. This helps the battery to recover its voltage. Do not race the engine unless required to do so. Abrupt throttle movement wastes fuel and may damage the engine.  25 Tip This model is equipped with an automatic ignition cut off circuit that stops the engine automatically if a gear is selected while the side stand is down. Always retract the side stand before selecting a gear. This model also has a safety feature that will not allow the engine to start if the machine is in gear. However, this can be overridden by pulling the clutch lever in while starting. Be careful not to let the clutch lever go until the transmission is placed in Neutral. 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. 5. Pull the choke lever upward to “ON”. 6. Close the throttle and press the starter button. 7. When the engine starts, gradually push the choke lever downward to “OFF” and warm up the engine until the rpm stabilizes, then push the choke lever all the way downward. 8. Check the side stand is retracted before riding.  Refer to p.70 if the engine fails to start. 26 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”. 5. Close the throttle and press the starter button. If the engine fails to start after one or two trials, follow procedure 6. 6. If the engine does not start with the throttle closed, open the throttle to 1/8 ~ 1/4 as shown in the diagram and press the starter button. 7. Check the side stand is retracted before selecting a gear. Refer to p.70 if the engine fails to start 27 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). You should be able to feel the gear changer click solidly into place. 28 Basic Operation _______________________________________________ Riding Tips  Check the side stand is retracted before riding – selecting a gear. Use the gears within the speed ranges given in the table. To save fuel and prolong the life of the motorcycle, avoid rapid acceleration or deceleration.   Gear 1st 2nd 3rd 4th 5th Advice If you notice any unusual sound or other problems, contact an authorized HONDA dealer as soon as possible.   Tip Accelerate as gently as possible. Always observe the speed limit. Running In Keep the engine in relatively lower rpm and avoid rapid acceleration and deceleration for the first 500km. This will prolong the life of the engine. 29 Speed Range 0-40 km/h 15-60 km/h 25-80 km/h 35-110 km/h 45 km/h and above Basic Operation _______________________________________________ 5th - 4th 4th – 3rd 3rd – 2nd 2nd – 1st Changing down the gears Changing down gears provides greater acceleration in situation such as overtaking. Avoid changing down at high speed, which can damage both the engine and the transmission by running the engine at excessively high rpm. The table shows the maximum speed for each shift down. 30 Maximum Speed 95 km/h 75 km/h 50 km/h 35 km/h Basic Operation _______________________________________________ Braking  For optimum braking performance, apply  front and rear brakes simultaneously.  Brake as gently as possible to avoid locking the wheels which makes the motorcycle unstable / uncontrollable.  In wet weather and on wet surfaces, the wheels become more likely to lock during braking, therefore stopping distance increases. Reduce riding speed and allow longer braking distance under such circumstances.  Avoid continuous braking to prevent overheating the brake system which causes brake fade and reduces the braking performance. Braking performance may be affected by puddles and wet weather. Always test the brakes gently after riding through such conditions (keep clear of other traffic and slow down first). If necessary, apply the brakes periodically whilst riding at reduced speed until they dry out. 31 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. Use a combination of the engine braking and intermittent braking on long or steep downhill slopes. 32 Maintenance Safety Tips _______________________________________________ Maintenance Safety Tips   Stop the engine and remove the key when servicing.   Park on a flat and stable surface using the side stand. 33 Maintenance Safety Tips _______________________________________________  Wait for the engine, the muffler and the exhaust pipe to cool before starting work.  Engine exhaust fumes contain carbon monoxide and other harmful substances. Do not run the engine in poorly ventilated area such as a closed workshop. 34 Maintenance Safety Tips _______________________________________________  If the motorcycle requires test riding, conduct in a safe place, away from other traffic.   Always use proper tools. Any servicing, repair or adjustment should be carried out by an authorized Honda dealer. 35 Maintenance _______________________________________________  To ensure the safety and comfort of riding your motorcycle, it is required to inspect some items daily and service the machine regularly. Caution Always comply with the correct servicing procedure. Failure to do so could result in fatal or severe injury.  Follow the procedures and guidelines given in this owner’s manual and the service manual.  Observe all service and maintenance schedules.  Fix all problems before you ride.  Inspection and maintenance procedures and requirements are described on the following pages. After the first month………………….. 36 Replacement parts…………………… 36 Daily (pre-ride) inspection…………… 37 Maintenance parts layout……………. 38 Regular service……………………….. 40 Maintenance Schedule...…………….. 41 Basic maintenance…………………….44 Engine oil……………………………….45 Drive Chain……………………………..50 Brakes…………………………………..52 Clutch…………………………………...54 Battery…………………………………..56 Fuses……………………………………59 Tyres…………………………………….61 Air filter………………………………….63 36 Maintenance _______________________________________________ After the first month Replacement parts The first service after one month (or 1000km) is crucial to the life of the engine. Contact an authorized Honda dealer for all service requirements. Your Honda dealer has all the expertise and technical information necessary to correctly service or repair your machine. Use only genuine Honda parts and oil when servicing the motorcycle. Honda parts and oil are designed specifically for Honda motorcycles and are subjected to rigorous examination procedures. Honda parts and oil are available from authorized Honda dealers and are identified by the Honda logo. Only Honda genuine parts are covered by a manufacturers warranty. Some conditions apply. 37 Maintenance _______________________________________________ Daily (pre-ride) Inspection All motorcycle riders are advised to carry out a daily pre-ride inspection to ensure safe and comfortable riding. Details of the daily inspection are given below. Underlined items are described in “Basic Maintenance ( pg.44 ). The diagrams on the following pages show the inspection parts. Daily (pre-ride) Inspection Checklist  Brakes - Lever free play (hydraulic) - Pedal free play (hydraulic) - Braking performance - Brake fluid level  Tyres - Air pressure - Cracks / damage - Abnormal wear - Tread (x)  Engine - Coolant level (x) - Engine oil level (4-stroke only) (x) - Starting noise (x) - Low speed / acceleration (x)  Lamps and turn signals  Any problems detected on the previous day. (x) = Check as appropriate in line with usage time and distance traveled. 38 Maintenance _______________________________________________ Maintenance Parts Layout Maintenance procedures and guidelines are given in “Basic Maintenance” pages of this manual. 39 Maintenance _______________________________________________ 40 Maintenance _______________________________________________ Regular Service – Minimum. Specifications are given on page 73. The XR400M requires the first one month (or 1000km) service and, at least, every 6000km thereafter. For optimum safety and comfort, conduct these regular services. It is your responsibility to have your motorcycle serviced by an authorized Honda dealer.     Record the results of every service in the service manual maintenance log and store in a safe place. 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. All repair work should be referred to an Authorized Honda Dealer. These instructions are based on the assumption that the motorcycle will be used exclusively for its designed purpose. Sustained high speed operation, or operation in unusually wet or dusty conditions will require more frequent service than specified in the MAINTENANCE SCHEDULE. Consult your authorised Honda dealer for recommendations applicable to your individual needs and use. 41 Maintenance _______________________________________________ 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. Perform the Pre-ride Inspection (pg 37) at each scheduled maintenance period. I: C: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY CLEAN R: REPLACE A: ADJUST L: LUBRICATE FREQUENCY ITEM * FUEL STRAINER SCREEN * THROTTLE OPERATION * CARBURETTOR CHOKE * AIR CLEANER CRANKCASE BREATHER SPARK PLUG * VALVE CLEARANCE ENGINE OIL ENGINE OIL FILTER ENGINE OIL STRAINER * SCREEN * ENGINE IDLE SPEED BRAKE FLUID ODOMETER READING NOTE (1) NOTE (p43) X 1,000km X 1,000mi MONTH 1 6 12 18 24 30 36 0.6 4 8 12 16 20 24 C 6 C 12 C I I I C R I R R 18 C 24 C I I I C R I R R 30 C 36 C I I R C R I R R NOTE (2) NOTE (3) I R R I C I I R R C I I R C I NOTE (4) 42 I I I I I C I I R C I R I I I I *Refer to Service Manual * * * - C - I R * - Maintenance _______________________________________________ FREQUENCY ITEM ODOMETER READING [NOTE (1)] NOTE X 1,000km 1 6 12 18 24 30 36 X 1,000mi 0.6 4 8 12 16 20 24 6 12 18 24 30 36 MONTH DRIVE CHAIN EVERY 1,000km (600mi) I, L DRIVE CHAIN SLIDER I BRAKE SHOE / PAD WEAR I BRAKE SYSTEM I I I I I I *Refer to Service Manual * I - I - I I I - * BRAKE LIGHT SWITCH I I I - * HEADLIGHT AIM I I I - I - CLUTCH SYSTEM I I I I I I SIDE STAND I I I - * SUSPENSION I I I * * NUTS, BOLTS, FASTENERS I I I - ** WHEELS / TYRES I I I - ** STEERING HEAD BEARINGS I I I * I I 43 Maintenance _______________________________________________  SHOULD BE SERVICED BY AN AUTHORISED HONDA DEALER, UNLESS THE OWNER HAS PROPER TOOLS AND SERVICE DATA AND IS MECHANICALLY QUALIFIED, REFER 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: 1. 2. 3. 4. At higher odometer readings, repeat at the frequency interval established here. Service more frequently when riding in unusually wet or dusty areas. Service more frequently when riding in rain or at full throttle. Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires mechanical skill. 44 Maintenance _______________________________________________ Basic Maintenance This section describes basic maintenance procedures that should be performed on a regular basis. 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. 45 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. Place the motorcycle on a flat surface. 2. Remove the Engine Oil Dipstick. 3. Wipe the oil from the Dipstick 4. Ensure that the motorcycle is upright and insert the Dipstick. Do not screw in. 5. If oil can be seen on the Dipstick, proceed to check the oil quantity (Page48). If Oil cannot be seen on the Dipstick: Remove oil check bolt and sealing washer on the right hand side of the crankcase. If Oil leaks from the check bolt hole: Refit the check bolt and sealing washer. Recheck the oil level as per the above procedure. 46 Maintenance ______________________________________________ If Oil does not leak from the check bolt hole: Refit the check bolt and sealing washer. Remove the dipstick and pour some oil into the frame. Re-insert the dipstick and recheck the oil level as per the above procedure. Wipe any spilt oil prior to starting the engine. Recommended Oil Genuine Honda oil for 4-stroke motorcycle. Honda GN4 10W – 30 ( General use ) Honda GN4 20W – 50 ( Hotter Areas )  Advice The engine oil also lubricates the clutch. Use of engine oils designed to reduce wear and tear on the engine could cause the clutch to slip, affect engine start up, degrade engine performance and even shorten the engine life. Do not use oil with additives or friction modifiers. Do not mix different brands / and or grades of oil and do not use oil that doesn’t match the chart, regardless of the quality. Use of such oil may cause engine damage or loss of performance. If you are using the products other than Honda, select from the following ranges.  API type: SJ grade  SAE rating: Select from the diagram on page 47.  Do not use oils containing Friction Modifiers. 47 Maintenance _______________________________________________ Temperature and Viscosity Choose the engine oil corresponding to the atmospheric temperature in your riding area. Oil change intervals. Initial: 1,000km After the first change: Every 6000km Contact an Authorized Honda Dealer for the oil change. 48 Maintenance Oil Quantity Check: 2. After warm up, let the motorcycle idle for about one minute, while holding the motorcycle upright. 1. Park the motorcycle on a flat, level surface. Start the engine and warm it up, particularly in cold climates. Warm up can be done with the motorcycle on its sidestand. After warm up, do not run the engine or let the motorcycle lean to one side. 49 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 – Top up the oil to the Max line if the level is low. 7. Refer to the information on the previous pages before adding engine oil. 8. Make sure you screw the dipstick back in fully after these checks. 50 Maintenance _______________________________________________ Drive Chain < Chain Slack Check > Place the motorcycle on the side stand and pull the chain up and down at the mid-point between the front and the rear sprockets. Measure the slack using a ruler. Drive chain slack: 15 ~ 25mm Adjust the slack if out of the range. 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. 51 Maintenance _______________________________________________ “Genuine Honda Chain Oil” < Lubrication and Cleaning > Chain Oil: Place the motorcycle on the side stand and clean mud or dirt from the chain and sprocket. Move the motorcycle back and forward to clean entire chain. Avoid steam cleaning as the chain has rubber seals. Apply lubrication oil to both sides of the chain roller so as to have the oil reach entire part of the chain. Excessive lubrication may result in spattering oil on the body or on your clothing. Or gear oil (#80 ~ #90). Advice Do not use chain spray and other lubrication oil containing solvents. They may shorten the life of the chain. 52 Brakes / Clutch _______________________________________________ Brakes Brake fluid level check < Front Brake > Place the motorcycle on flat surface and set the side stand. Move the handlebar to make sure the reservoir cap surface is level Check the fluid level is above the lower limit line (minimum line). < Rear Brake > Hold Motorcycle upright and check that fluid is between Upper and Lower marks on the 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. 53 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. Contact an Authorized Honda Dealer for brake pad replacement and always use Genuine Honda Brake Pads. Always replace brake pads as a set – failure to do so may cause uneven braking or instability. 54 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). 55 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. Start the engine and try changing gears. If the changes are jerky or the engine stalls or starts to move, re-adjust the free play. 56 Battery _______________________________________________ Battery The XR400M is equipped with a Caution maintenance free battery. Battery fluid level The diluted sulphuric acid electrolyte is check or refill are not required. Keep the highly corrosive and can cause severe battery terminals free of dirt and corrosion. burns if it comes in contact with the eyes or skin. Battery Handling  Wear protective goggles and clothing  Keep the battery away from fire or when working near the battery. sparks.  Keep the battery out of reach of  Battery fluid is diluted sulphuric acid. children. Do not allow contact with skin or eyes.    Advice Do not remove the fluid filler cap. The battery is fully sealed. No need to remove the cap even when charging. “Jump starting” a flat battery may cause damage to the battery plates or cells. Charge the battery rather than use “Jumper Leads”. Emergency Treatment  If the electrolyte gets in the eyes:  Flush with water from a glass for at least 15 minutes. Avoid pressurized water as it may harm the eyes.  If the electrolyte contacts the skin:  Remove the clothes and wash the skin with plenty of water.  If the electrolyte is swallowed:  Drink water or milk – do not induce vomiting. In any case, consult a doctor immediately. 57 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. If the battery is to be replaced, replace with the maintenance free battery. < Ensure that you dispose of the old battery correctly and in line with EPA requirements> 58 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. 5. Remove the battery from its holder. Installation 1. Connect the positive lead first. 2. Secure the bolts / nuts. 59 Battery / Fuses _______________________________________________ Fuses < Fuse inspection / replacement > Turn off the ignition switch before checking the fuses. Replace blown fuses with the fuses of same rating. Never use higher-rating fuses. They may cause overheating and electrical system damage. If a new fuse blows soon after replacement, there may be a fault in the relevant electrical system. 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. 60 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. Main fuse 1. Remove the Left hand Side Cover. 2. Disconnect the starter solenoid coupler. 3. Pull out and check the main fuse. Replace if necessary with the spare fuse located behind the battery box. 4. Reconnect the coupler and install the side cover. 61 Tyres _______________________________________________ Tyres Tyres should be kept in good condition and maintained at the rated pressure at all times. Worn tyres should be replaced immediately. < Tread > Tyres should be replaced as soon as wear indicators start to appear on the tyre wall, or when the tread on the centre of the tyre reaches the level shown below. Caution Use of worn tyres or failure to maintain tyres at the correct pressure can cause an accident resulting in serious injury or death. Always maintain tyres at the correct pressure given in this owner’s manual, and replace worn tyres immediately. < Air pressure > Check the air pressure while the tyres are cold. Without pillion passenger With pillion passenger 62 Front 2.25kgf/cm² Rear Front 2.50kgf/cm² 2.25kgf/cm² Rear 2.50kgf/cm² Tyres _______________________________________________ < Replacement Tyres > Replace with only the approved tyre types given below. Use of other types can affect handling and stability. Contact an Authorized Honda Dealer when replacing a tyre. FRONT Size Type REAR Size Type Warning Use of tyres other than the designated tyres in the table can affect handling and stability and could cause serious injury or death. Replace tyres only with the approved types given in this owner’s manual or equivalent. 110 / 70 – 17MC 54H Bridgestone GT401FK Tubeless 140 / 70R – 17MC 66H Bridgestone GPR80 Tubeless 63 Air Filter _______________________________________________ Air Filter < Replacing the air filter > The oil-soaked viscous air filter element should be inspected regularly, as per the Maintenance Schedule and should be replaced, at least, every 18,000km. Under severe conditions the filter should be inspected and replaced more regularly. 1. Release the Left Hand Side Cover Release Screws. 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. 64 Cleaning _______________________________________________  To prevent internal rust and potential starting problems, keep water out of the muffler.  Keep brake parts dry. Water in the brake mechanism affects braking performance.  Polish painted surfaces and plastic parts gently. Strong rubbing with wax or polishing compounds can wear down the paint coating and cause discoloration.  Dry and lubricate any moving parts that may be affected by water. After cleaning the motorcycle, start the engine and test the brakes (keep clear of other traffic and keep a low speed). If necessary, apply the brakes periodically while riding at reduced speed until they dry out. 65 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. To prevent scratching, avoid abrasive cleaners and steel wool and do not use excessive force when cleaning or rubbing aluminum parts. 66 Damper Units Environmental Consideration _______________________________________________ Damper Units Environmental Consideration The damper units contain compressed Nitrogen Gas which should be released prior to disposal. Contact an Authorized Honda Dealer when the damper units require replacement. For environmental consideration, please handle used batteries, tyres and engine oil properly in terms of environmental matters. Warning Do not throw the damper unit into fire or disassemble the unit. It may explode which could cause serious injury or death. Please do not:  Throw into fire  Drill a hole in it, or  Disassemble 67 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. 68 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. This damage will not be covered by Warranty. 69 Vehicle Identification Numbers ______________________________________________ Vehicle Identification Number (VIN) Engine Number The VIN is required when ordering parts and registering your motorcycle, and can also be helpful if the motorcycle is stolen. When ordering engine parts, the engine number can also be required, to identify correct engine model. Write down the VIN number together with the vehicle registration number and store in a safe place. Write down the Engine Number and store it with the VIN number and registration documents. 70 Engine Troubleshooting _______________________________________________ < If the Engine stalls, or does not start, check the following > Breather Cleaning Procedure 1. Place an oil pan under the Breather Drain. 2. Remove the Drain Plug and remove all build-up inside the Breather Drain. 3. Refit the Breather Drain Plug to the correct torque. 1. That the engines is started in accordance with the starting procedure in this manual. 2. That there is sufficient Fuel in the tank. 3. That the Engine Stop Switch is in the “RUN” position – If the Switch is in the “OFF” position, please follow the procedure below. (a) Leave the Engine Stop switch in the “OFF” position. (b) Make sure the Choke is fully open and fully open the Throttle. (c) Turn the Ignition Switch to “ON”. (d) Engage the Starter for 5 – 10 Seconds to crank the engine. (e) Now, set the Engine Stop switch to “RUN” and follow the starting procedure elsewhere in this manual. 71 Specifications _____________________________________________ Type Overall length Overall width Overall height Wheelbase Engine type / volume Dry weight Maximum capacity Front Tyre size ND08 2140mm 810mm 1140mm 1450mm 4-stroke, petrol / 0.397L 145kg 2 People 110/70 – 17M/C 54H Minimum ground clearance Fuel consumption Minimum turning radius Compression ratio 140/70R – 17M/C 66H 220mm 36.0km/l (@60km/h) 2.2m 8.8 Maximum output power Maximum torque Engine oil capacity Fuel tank capacity 22kW (30ps) / 7,000rpm 33N.m(3.4kg-m) / 5,500rpm 2.2 Litres 9.7 Litres Rear 72 Specifications _______________________________________________ Ignition system Ignition timing Idling speed Spark plugs NGK DENSO Battery Reduction ratio between engine and gearbox Clutch type Gearbox type Gear change mechanism ST Gear ratio 1 ND 2 RD 3 TH 4 TH 5 Final reduction ratio 73 CDI BTDC 8° / 1400rpm 1300rpm DPR8Z DPR9Z X24GPR-U X27GPR-U 12V – 6AH 2.666 Wet multi-plate coil spring Constant mesh transmission Left foot pedal 2.615 1.789 1.350 1.076 0.892 2.466 Specifications _______________________________________________ Tyre pressure Drive chain slack Driver only Driver and passenger Engine oil 15 – 25mm Front 2.25 kgf/cm² Rear 2.50 kgf/cm² Front 2.25 kgf/cm² Rear 2.50 kgf/cm² Total capacity Oil filter change Oil change Clutch lever free play Fuses Main fuse Other fuses Spark plug gap Air filter element Type Bulbs Headlamp Stop / Tail Lamp Front turn signals Rear turn signals 74 2.2L 1.8L 1.7L 10 – 20mm 20A 5A, 15A 0.6 – 0.7mm Viscous filter type 12V – 60/55W 12V – 21/5W 12V – 15W 12V – 15W _______________________________________________ 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 its sale or delivery to the ultimate purchaser or while it is in use: and (b) The use of the motorcycle after such device or element of design has been removed or rendered inoperative by any person. 75