Dimensions
Length: 2130 mm (83.9 in)
Width: 840 mm (33.1 in)
Height: 1240 mm (48.8 in)
Wheelbase: 1425 mm (56.1 in)
Seat Height: 930 mm (36.6 in)
Ground Clearance: 310 mm (12.2 in)
Dry Weight: 116.5 kg (257 lbs)
Curb Weight: 125 kg (256 lbs)
Maximum Weight Capacity: 100 kg (220 lbs)
Frame
Frame Type: Semi-double cradle
Front Suspension: Telescopic fork
Front Wheel Travel: 280 mm (11.0 in)
Rear Suspension: Swingarm
Rear Wheel Travel: 300 mm (11.8 in)
Front Tyre (Tire) Size: 80/100-21 51M
Rear Tyre (Tire) Size: 110/100-18 64M
Tyre (Tire) Brand (Dunlop) FR/RR: K490G/K695
Front Brake: Hydraulic single disc
Rear Brake: Hydraulic single disc
Caster Angle: 25 degrees 15'
Trail Length: 94 mm (3.7 in)
Fuel Tank Capacity: 9.5 l (2.5 US Gal, 2.1 Imp Gal)
Fuel Tank Reserve Capacity: 1.5 l (0.4 US Gal, 0.3 Imp Gal)
Engine
Cylinder Arrangement: Petrol (Gasoline), air cooled 4-stroke SOHC
Bore and Stroke: 85.0 x 70.0 mm (3.35 x 2.76 in)
Displacement: 397 cm cubed (24.2 cu-in)
Compression Ratio: 9.3:1
Valve Train: Silent multi-link chain driven SOHC with rocker arms
Intake Valve Opens at 1 mm Lift: 11 degrees BTDC
Intake Valve Closes at 1 mm Lift: 41.5 degrees ABDC
Exhaust Valve Opens at 1 mm Lift: 40 degrees BBDC
Exhaust Valve Closes at 1 mm Lift: 10 degrees ATDC
Lubrication System: Forced pressure (dry sump)
Oil Pump Type: Trochoid
Cooling System: Air cooled
Air Filtration: Oiled polyurethane foam
Engine Weight: 38.5 kg (85 lbs)
at draining 1.7 l (1.8 US qt, 1.5 Imp qt)
at disassembly 2.2 l (2.3 US qt, 1.9 Imp qt)
at filter change 1.8 l (1.9 US qt, 1.6 Imp qt)
Recommended Engine Oil: Honda GN4 or HP4 4-stroke oil or equivalent motor oil. API service classification: SF or SG Viscosity: 10W-40 or 20W-50.
Oil Pump Rotor:
Tip clearance: 0.15 (0.006)
Body clearance: 0.15 - 0.22 (0.006 - 0.009)
End clearance: 0.02 - 0.09 (0.001 - 0.004)
Fuel System
Carburettor Identification Number: *Note - Other countries may have different models.
'96, '97: PDK1A
After '97 (49 State Type): PDK1C
After '97 (California Type): PDK1E
Main Jet: *Note - Other countries may vary jet sizes.
'96, '97: #162 (standard setting), #158 (suggested settings for trail riding)
After '97: #142
Slow Jet: *Note - Other countries may vary jet sizes.
'96, '97: #62 (standard setting), #60 (suggested settings for trail riding)
After '97: #52
Jet Needle Clip Position: *Note - Other countries may vary clip positions.
'96, '97: 3rd groove from top (standard setting), 2nd groove from top (suggested settings for trail riding)
After '97: 3rd groove from top
Pilot Screw Opening: Factory setting 2 1/4 turns out
Float Level: 14.5 mm (0.57 in)
Idle Speed: 1300 +/- 100 rpm
Throttle Grip Free Play: 2 - 6 mm (1/8 - 1/4 in)
Clutch
Clutch Lever Free Play: 10 - 20 (3/8 - 3/4)
Clutch Spring Free Length:
'96: 45.5 (1.79) Service Limit - 44.5 (1.75)
After '96: 43.2 (1.70) Service Limit - 41.6 (1.64)
Clutch Disc Thickness: 2.92 - 3.08 (0.115 - 0.121) Service Limit 2.69 (0.106)
Clutch Plate Warpage Service Limit: 0.30 (0.012)
Front Wheel / Suspension / Steering
Cold Tyre (Tire) Pressure: 100kPa (15 psi)
Front Wheel Rim Runout Service Limit: Radial 2.0 (0.8 ), Axial 2.0 (0.8 )
Fork Spring Free Length:
'96, '97: 510.4 (20.09) Service Limit 505.3 (19.89)
After '97: 536.1 (21.11) Service Limit 528 (20.8 )
Fork Spring Direction: Narrow end facing down
Fork Tube Runout Service Limit: 0.20 (0.0008 )
Fork Air Pressure: 0 kPa
Recommended Fork Oil: Pro Honda Suspension Fluid SS - 7
Fork Oil Level:
'96, '97: 100 (3.9)
After '97: 116 (4.6)
Fork Oil Capacity:
'96, '97: 570 cc
After '97: 559 cc
Rear Wheel / Suspension
Cold Tyre (Tire) Pressure: 100 kPa (15 psi)
Rear Wheel Rim Runout Service Limit: Radial 2.0 (0.8 ), Axial 2.0 (0.8 )
Drive Chain Slack: 35 - 45 (1 1/3 - 1 3/4)
Drive Chain Length (at 41 pins / 40 links) Service Limit: 638 (25.1)
Drive Chain Size / Link: DID 520V8/108 or RK520M0Z6/108
Chain Slide Depth Service Limit: 4.0 (0.15)
Shock Absorber Spring Free Length: 217.3 (8.56) Service Limit 213.0 (8.39)
Shock Absorber Spring Direction: Narrow end facing down
FR: 3.0 (0.12) Service Limit 2.5 (0.10)
RR: 4.5 (0.18 ) Service Limit 4.0 (0.16)
Brake Disc Runout: Service Limit 0.25 (0.010)
Electrical System
AC Regulator Regulated Voltage: 12/5 - 13.5 V / 3000 rpm
Spark Plug:
Standard Riding: NGK DPR8Z, DENSO X24GPR-U
High Speed Riding: NGK DPR9Z, DENSO X27GPR-U
Spark Plug Gap: 0.6 - 0.7 (0.023 - 0.028 )
Headlight Bulb: 12 V 35 W
Taillight Bulb: 12V 5 W
Torque Values
Unless specified all bolts should be tightened to the following torque values.
Standard Fasteners N-m (kgf-m, lbf-ft):
5 mm Bolt and Nut: 5 (0.5, 3.6)
6 mm Bolt and Nut: 10 (1, 7)
8 mm Bolt and Nut: 22 (2.2, 16)
10 mm Bolt and Nut: 34 (3.5, 25)
12 mm Bolt and Nut: 54 (5.5, 40)
5 mm Screw: 4 (0.4, 2.9)
6 mm Screw: 9 (0.9, 6.5)
6 mm Flange Bolt (8 mm Head: Small Flange): 9 (0.9, 6.5)
6 mm Flange Bolt (8 mm Head: Large Flange - engine only): 12 (1.2, 9)
6 mm Flange Bolt (10 mm Head) and Nut: 12 (1.2, 9)
8 mm Flange Bolt and Nut: 26 (2.7, 20)
10 mm Flange Bolt and Nut: 39 (4.0, 29)
Engine N-m (kgf-m, lbf-ft):
Oil Drain Bolt (at crankcase) 1 x 12 mm: 25 (2.5, 18 )
Oil Drain Bolt (at frame down tube) 1 x 10 mm: 39 (4.0, 29)
Frame Down Tube Oil Strainer Screen 1 x 27 mm: 54 (5.5, 40)
Oil Pipe Bolt (at Oil Strainer Strainer) 1 x 12 mm: 37 (3.8, 27)
Oil Cooler Joint Flare Nut (left side) 1 x 16 mm: 20 (2.0, 14)
Oil Cooler Joint Flare Nut (right side) 1 x 16 mm: 20 (2.0, 14)
Oil Pump Assembly Bolt 2 x 6 mm: 13 (1.3, 9)
Fuel Valve Mounting Bolt 2 x 6 mm: 9 (0.9, 6.5)
Spark Plug 1 x 12 mm: 18 (1.8, 13)
Valve Hole Cap 4 x 36 mm: 15 (1.5, 11)
Valve Adjusting Lock Nut 4 x 7 mm: 24 (2.4, 17)
Head Cover Bolt 1 x 8 mm: 26 (2.7, 20)
Rocker Arm Shaft 2 x 14 mm: 27 (2.8, 20) NOTE 1
Intake Sub-Rocker Arm Shaft 2 x 14 mm: 27 (2.8, 20) NOTE 1
Exhaust Sub-Rocker Arm Shaft 2 x 14 mm: 27 (2.8, 20) NOTE 1
Cam Sprocket Bolt 2 x 7 mm: 20 (2.0, 14) NOTE 1
Cam Chain Tensioner Plug 1 x 6 mm: 4 (0.4, 2.9)
Cylinder Head Nut 4 x 10 mm: 44 (4.5, 33) NOTE 2
Cylinder Bolt 4 x 10 mm: 44 (4.5, 33) NOTE 2
Kickstarter Pedal Pinch Bolt 1 x 8 mm: 26 (2.7, 20)
Clutch Center Lock Nut 1 x 18 mm: 108 (11.0, 80) NOTE 2, 4
Gearshift Drum Stopper Arm Pivot Bolt 1 x 6 mm: 12 (1.2, 9)
Primary Drive Gear Nut 1 x 18 mm: 88 (9.0, 65) NOTE 2
Timing Hole Cap 1 x 14 mm: 10 (1.0, 7)
Crankshaft Hole Cap 1 x 30 mm: 8 (0.8, 5.8 )
Flywheel Bolt 1 x 12 mm: 127 (13.0, 94) NOTE 2
Left Crankcase Cover Stud Bolt 1 x 6 mm: 10 (1.0, 7) NOTE 1
Frame N-m (kgf-m, lbf-ft):
Sub-Frame Upper Mounting Nut 1 x 8 mm: 26 (2.7, 20)
Sub-Frame Lower Mounting Nut 2 x 8 mm: 42 (4.3, 31)
Exhaust Pipe Joint Nut 4 x 8 mm: 18 (1.8, 13)
Muffler Mounting Bolt 2 x 8 mm: 32 (3.3, 24)
Muffler Band Bolt 1 x 8 mm: 20 (2.0, 14)
Right Foot Peg Mounting Bolt 2 x 10 mm: 42 (4.3, 31)
Gearshift Pedal Pinch Bolt 1 x 6 mm: 12 (1.2, 9)
Front Axle Holder Nut 8 x 6 mm: 12 (1.2, 9)
Front Axle 1 x 16 mm: 88 (9.0, 65)
Front Brake Disc Bolt 4 x 6 mm: 20 (2.0, 14) NOTE 1
Front Rim Lock 1 x 8 mm: 13 (1.3, 9)
Fork Center Bolt 2 x 22 mm: 34 (3.5, 25) NOTE 1
Fork Cap 2 x 39 mm: 23 (2.3, 17)
Steering Stem Nut 1 x 24 mm: 98 (10.0, 72)
Rear Axle Nut 1 x 16 mm: 88 (9.0, 65)
Rear Brake Disc Bolt 4 x 8 mm: 42 (4.3, 31) NOTE 3
Driven Sprocket Bolt 6 x 8 mm: 32 (3.3, 24)
Rear Rim Lock Nut 1 x 8 mm: 13 (1.3, 9)
Shock Absorber Upper Mounting Nut 1 x 10 mm: 44 (4.5, 33)
Shock Absorber Lower Mounting Nut 1 x 10 mm: 44 (4.5, 33)
Shock Arm-to-Swingarm Nut 1 x 12 mm: 69 (7.0, 51)
Shock Link-to-Frame Nut 1 x 10 mm: 49 (5.0, 36)
Shock Link-to-Shock Arm Nut 1 x 10 mm: 44 (4.5, 33)
Swingarm Pivot Nut 1 x 14 mm: 88 (9.0, 65)
Chain Adjuster Stopper Pin 2 x 10 mm: 34 (3.5, 25) NOTE 1
Brake Hose Oil Bolt 4 x 10 mm: 34 (3.5, 25)
Pad Pin 2 x 10 mm: 18 (1.8, 13)
Pad Pin Plug 2 x 10 mm: 2.5 (0.25, 1.8 )
Caliper Bleed Valve 2 x 8 mm: 5.5 (0.55, 4.0)
Front Caliper Mounting Bolt 2 x 8 mm: 30 (3.1, 22) NOTE 3
Front Caliper Pin Bolt 1 x 8 mm: 23 (2.3, 17) NOTE 1
Front Caliper Bracket Pin Bolt 1 x 8 mm: 13 (1.3, 9) NOTE 1
Rear Caliper Pin Bolt 1 x 12 mm: 27 (2.8, 20)
Rear Caliper Bracket Pin Bolt 1 x 8 mm: 13 (1.3, 9) NOTE 1
Rear Master Cylinder Mounting Bolt 2 x 6 mm: 14 (1.4, 10) NOTE 3
Rear Master Cylinder Push Rod Lock Nut 1 x 8 mm: 18 (1.8, 13)
Side Stand Pivot Bolt 1 x 10 mm: 10 (1.0, 7) NOTE 5
Side Stand Pivot Nut 1 x 10 mm: 39 (4.0, 29)
NOTE 1: Apply locking agent to the threads.
NOTE 2: Apply oil to the threads and seating surface.
NOTE 3: ALOC bolt. Do not reuse.
NOTE 4: Stake.
NOTE 5: Loosen the bolt 1/8 turns to 1/4 turns after tightening it to the specified torque, then tighten the pivot nut.
Originally posted by bluefairy at 2009-4-15 10:50:
XR400R 具有250的一切優點..只是馬力變成由30匹變成40匹/7500RPM ,扭力由2.6公斤放大為 4.21KG/6000 RPM....車重多10公斤...操縱一樣靈活輕快,簡單耐用...如此的好車,可遇而不可求....這麼好的車哪裡買呢??