Honda XR400 Service Manual


I recently obtained the Honda XR400 Service Manual and wanted to share. Apparently, this manual is for all Honda XR400’s from all years. I only know that is has comments about Pre-1996 and Post-1996 bikes.

If you do any amount of maintenance on your steed, you absolutely want / need the service manual.
Edit: I used to have it. See notes below.

So without further ramblings, here is more information:

Sorry — The free download of this manual is in violation of Honda’s Copyright laws and has been removed. You can purchase this manual online from

Please do NOT email me for a copy of this manual. I will not be able to fulfill your request.

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37 Responses to Honda XR400 Service Manual

  1. MXGuy says:

    I’m not sure either… though I think you can hold down the apple key while you click on the link. That might give you options, otherwise, yeah, get it tomorrow.

    Hopefully it’s helpful when you do get it. 🙂


  2. David says:

    Thanks MXGuy! I was able to download and it sure answered all my concerns right now!

  3. MXGuy says:

    Now that’s good news. Glad you got it.

  4. Ratko says:

    Thanks a lot for the manual. It will be of great help to me.

  5. Allen says:

    Hi. I have a 2003 XR 400 bought new and I had hard time starting too even worse in cold. I talked to Honda Service manager and he told me that Honda always jetted the bikes too lean meaning not enough gas and I ordered a bigger size slow jet and put it in. Now it starts easy. I suggest changing the slow jet and adjust the screw on bottom of carb. I forgot what it is and what its for..

  6. Billy says:

    so did honda contact you, and tell you to remove it? or did you just do it?

  7. MXGuy says:

    I was not contacted directly by Honda, but by a 3rd party that handles these sorts of things. Sorry, I was happy to share, but the cost of sharing at this point just isn’t worth the risk.

  8. stuart says:

    I am living in Costa Rica, Just bought a 2008 honda falcon nx4. I have problems with the valves and too much smoke out the exhaust??? Is the xr 400 similar enough to this engine? I have no problem buying the manual if it is the same? Thanks for your time!

  9. MXGuy says:

    Sorry Stuart, I am not familiar with the NX4, so I can’t say either way.

  10. Pedro says:

    I would like to get in touch with João Gonçalves (who posted in this site in Dec 20, 2008). Could you please send him my email? It’s about a XR400R.
    Thanks in advance

  11. James Koopman says:

    I got a 2002 Honda XR400 I would love to know a easy way to start this motorcycle.
    I have tried everything even taken back to the dealer twice and it still is a nitemare to start.
    I have a Honda XL500 A Honda TL250 both of those bikes can sit for a year and they still start. NO PROBLEM
    The XR400 is a Nitemare. I have had the Motorcycle six months and take it to ride and it never starts.
    This is the first Honda that does this.
    Need Help.

  12. Chris says:

    RE: James,

    My starting methods is tap on, Ignition off, full choke, decompress in, 5 or so kicks, by this time I can start to smell fuel then decompress out ignition on, work it to TDC give a big kick and it should be going.

    I’m a fairly skinny guy at 65kg / 145lbs and its fairly easy.


    Perth, Western Australia

  13. Adam Wallis says:

    I’ve recently purchased a 2005 XR400R as my first bike and am naturally looking for as much info as I can get that is going to help me service the bike to a high standard. I followed the link but found that the service manuals for the XRs only go to the 2004 model. Just wondering if a 2004 XR400R service manual would be relevant to my 2005 model and be beneficial in helping my service the bike? Is an owners manual all you need?

  14. Chris says:

    The bike never really changed after 2000, the owners manula is also here

  15. Chris says:

    The bike never really changed after 2000, the owners manula is also here

  16. Peter Velkoborsky says:

    Could I get anywhere some acces to download Repairs Manual for Honda XR 400 ?
    Thanks for your Owners Manual ! Peter V.

  17. mansur says:

    hey MXguy,

    My father have the XR250R and XR400R coz he’s a great fan of the XR’s. Unfortunately, he passed away few months now. And now im riding his bikes. So, i want to know what are the basic maintenance for this kind of bikes (e.g. engine oil,spark plugs,brake pads, etc.) what are the precautions to it. I wanna know all this things. I don’t want to sell the bikes, im keeping it in memory of my father.


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