HONDA XLAOOR XL500R ST Waa te WERKSTATT-HANDBUGH Pa HQNOA MOTOR Go. LTD 1862 Cea ma nism ana Uli LC asXL400R - XL500R ADDENDUM HONDA XL400R-500R INTRODUCTION This Addendum contains information for the XLA400R and XLSOOR. Refer to the base shop manual for service information not included in this addendum. The XL400R (F type) can be used the above base Manual. ALL INFORMATION, ILLUSTRATIONS, DIREC- TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LAT- EST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING HONDA MOTOR CO,, LTD, RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER. Courtesy of Hondaxl.it - www.hondaxl.it ny HONDA MOTOR CO., LTD. Service Publications Office INTRODUCTION Ce supplément renferme des informations pour la XLA400R et XLSOOR. Se reporter au manuel atelier principal pour les informations d'entre- tien gui n'y sont pas données. La XL400R (type F) suit les explications du Manuel d’atelier de base. TOUTES LES INFORMATIONS, ILLUSTRA TIONS. INSTRUCTIONS ET CARACTERISTI- QUES DE CETTE PUBLICATION S'APPUIENT SUR LES DERNIERES DONNEES SUR LE PRO- DUIT DISPONIBLES AU MOMENT DE LA MISE SOUS PRESSE. LA HONDA MOTOR CO., LTD. SE RESERVE LE DROIT D'EFFECTUER DES MODIFICATIONS A TOUT MOMENT. SANS AUTRE AVERTISSEMENT ET SANS AUCUNE OBLIGATION DE SA PART. Courtesy of Hondaxl.it - www.hondaxt.it HONDA MOTOR CO., LTD. Bureau des Publications d’Entretien CONTENTS GENERAL INFORMATION ..........--- LUBRICATION = 22-1 INSPECTION AND ADJUSTMENT . 22-11 FUEL SYSTEM ...... 005 aime geen emit CYLINDER HEAD ....-.seeeee sintenety SBE GLUTCH/OIL PUMP... + 22-26 AC GENERATOR FRONT WHEEL/BRAKE/ SUSPENSION/STEERING ...........-- REAR WHEEL/BRAKE/SUSPENSION BATTERY/CHARGING SYSTEM .- IGNITION SYSTEM . SWITCHES 1.250 iy ee seve TECHNICAL FEATURES . WIRING DIAGRAM TABLE DES MATIERES INFORMATIONS GENERALES , GRAISSAGE . aaa 224 CONTROLES ET REGLAGES ......... 22-1 CIRCUIT D'ESSENCE 0... 6. ce ceee eee 2221 CULASSE ...-. 6c ens 22-2, EMBRAYAGE/DOMPE A HUILE 22-2 ALTERNATEUR - ee 222-3 ROUEIFREINSUSPENSION/DIRECTION AVANT . ‘RETR ICApTRE NT ee eee ROUT/FREIN/SUSPENSION ARRIERE. .. . 22-5 BATTERIE/CIRCUIT DE CHARGE . 227 CIRCUIT D'ALLUMAGE ..... 2... -.... 228 COMMUTATEURS 2.26.00: 600008 res PARTICULARITES TECHNIQUES 22-9, SCHEMA DE CABLAGE 22-9: 22-1HONDA XL400R:XL500R ADDENDUM www hondaxlit XL400R+5O0R GENERAL INFORMATION SPECIFICATION ITEM XL500R AREA XLA0oR Overall length 2,186 mm (848in) 6 25410 mm (83.1 in}: a 2,110 mm (83.1 in) F 2 2,210 mm (87.0 in) ED Z| Overall width 865 mm (34.1 in) a | Overatt neight 1,260 mm (49.6 in) ——— S | whee! base 1,405 mm (55.3 in) Mecpacosat 5 | Seat height ‘895 mm (36.2 in} oa Ground clearance 270 mm (10.6 in) 5 creer Dry weight 139 kg (306 1b) 198 kg (304 1b) Frame type Diamond aL Front suspension, travel Telescopic, 215 mm (8.5 in? —— Rear suspension, travel Proslink, 190 mm (7.5 in) ———— Front tive size, pressure 3.00-21-4PR aA 150 KPa (1.5 kg/em?, 21 psi) gar A Rear tire size, pressure 4.60-17-4°R >——— | 150 kPa (1.5 ka/em?, 21 psi) ———— uy | Front brake, swept area Internal expanding shoes — 3 102 cm? (15.8 sq in} a & | Rear brake, swopt area Internal expandling shoes = aie oe 122 em? (18.9 sq in) — Fuel capacity 10 lit (2,6 US gal, 2.2 Imp gall SS Fuel reserve capacity 2lit (0.5 US gal, 0.4 Imp gal) — Coster ar” — Teail 118 mm (4.6 in} —<—— Front fork oil capacity/oil level | 378.8cc (12:8US 07)/163.0 mm ———S (6.42 in) SISO] FIRST 63] eS SSE WE (e) Tem 8 /8e/s €) Bs eek = $8, Se /se we A EVERY. S/eg/ Ars (SS =[(@) FUEL LIN i 1 1 fl =]ta) FUEL STRAINER € eke lice (6) THROTTLE OPERATION 1 Tals teal *|t6) CARBURETOR-CHOKE =| 1 < i (2) AIR CLEANER [(asiNoTE reine (8) CRANKGASE BREATHER (a4) NOTE? ¢ Lele (9) SPRAK PLUG a a *]t10) VALVE CLEARANCE T inti (30) REPLACE EVERY (11) ENGINE O1L a (28) YEAR| R 2,000 ri (3.200 ken) * 12) OIL FILTER SCREEN = € pie c (13) BALANCER CHAIN TENSION A A A * |(14) STARTER DECOMPRESSOR *|(16) CARBURETORDLE SPEED [1 | Page 3-9 (16) DRIVE CHAIN (GEINOTES | irites]|_Page 22-15 (17) BATTERY (20}MONTH] 1] Page 3-13 (18) BRAKE SHOE WEAR TP rr Er J Page 3-13 (19) BRAKE SYSTEM GP (ii xe | Ea Be * 20) BRAKE LIGHT SWITCH ‘| Sa 1_|-1_| Page 3-16 *(@1) HEADLIGHT AIM, ir tifa 1 [1 [Page 316 (22) CLUTCH i felt (23) SIDE STAND r me * |(24) SUSPENSION ne ' 1 * |(25) NUTS, 6 = (26) WHEELS/SPORES - (27) STEERING HEAD BEARING 1 1 ae SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER, UNLESS THE OWNER HAS PROPER ‘TOOLS AND SERVICE DATA AND IS MECHANICALLY QUALIFIED, IN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY AN AUTHOR. IZED HONDA DEALER. NOTES: 1, SERVICE MORE FREQUENTLY WHEN RIDING IN DUSTY AREAS. 2. SERVICE MORE FREQUENTLY WHEN RIDING IN RAIN OR AT FULL THROTTLE. 3. INITIAL SERVICE PERIOD: 300 km (200 miles). 4, SERVICE MORE FREQUENTLY WHEN RIDING OFF-ROAD. 5. FOR HIGHER ODOMETER READINGS, REPEAT AT THE FREQUENCY INTERVAL ESTABLISHED. HERE, 22-9HONDA xL400 XL400R-500R L500R ADDENDUM www.handaxl.it LUBRICATION © LUBRICATION POINTS i) eaneAn PivoT Ben) (1) THROTTLE GRIP ja)_ SPECIAL LUBRICANT © SHOCK ABSORBER UPPER MOUN” BUSHINGS {page 22-70) © SUSPENSION LINKAGE PIVOTS (2) CONTROL GABLES AND SPEEDOMETER CABLE (page 22-74) sc) (3) STEERING HEAD (15) REAR BRAKE BEARINGS nears “hh (16) BRAKE CAM (a) FRONT FORK (ATF) Bo) (6) BRAKE CAMS (11) DRIVE CHAIN (8) ENGINE (7) SPEEDOMETER GEAR 1 i | 1 I 1 1 | 1 \ | ' 1 \ t i 7 \ \ | ! | | \ | i ' \ ' i | (12) WHEEL BEARIT (8) WHEEL BEARING (9) BRAKE PEDAL PIVOT (10)SIDE STAND PIVOT 22-10XL400R-XL500R ADDENDUM HONDs XL400R-5001 ‘www.handaxl it @ ENGINE OIL RECOMMENDATION API SERVICE CLASSIFICATION: SE or SF ‘Other viscosities shown in the chart may be used when the average temperature in your riding area is within the indicated range. INSPECTION AND ADJUSTMENT FUEL STRAINER Turn the Fuel valve OFF. Remave the fuel cup, O-ring and filter screen, draining the gasoline into a suitable container, or _ | Gasoline ix flammable and is explosive under certain conditions. Do nor smoke or allow flames or sparks near the equipment wiile draining fuel, Wash the cup and filter screen in clean non- flammable or high flash point solvent. Reinstall the screen securely, aligning the index ‘marks on the fuel valve body and filter sereen, Install a new O-ring into the fuel valve body, Reinstall the fuel cup, making sure the new (Qrring is in place, Hand tighten the fuel cup and then torque it ta specification. TORQUE: 3-5 N-m (0.3-0.5 kgm, 2-4 ftb) After installing, turn the fuel valve ON and check thet there are no fuel leaks, (i) RECOMMENDED OIL VISCOSITY ty EDTEOPOIE) (1) FUEL CUP 0) O-RING (2) SCREEN (3) FUEL CUP 22-11HONDA XL400R-500R XL400R:XL500R ADDENDUM www.hondaxlit (1) BOLTS @ AIR CLEANER Remove the left side cover. Remove the air cleener caver bolts and the cover. (2) AIR CLEANER COVER (1) WING NUT Remove the wing nut and remove the air cleaner element. Wash the element in non-flammable or high flash point solvent, and let it dry. Soak the element in gear oil (SAE #80-90) and squeeze out the excess. Installation is the reverse order of disassembly. 4 (1) WASH. IN (2) SQUEEZE OUT (4) GEAR OIL SOLVENT SOLVENT (SAE#80-90) THROUGHLY, (5) SQUEEZE 0! EXCESS OIL 22-12XL400R°XL500R ADDENDUM www.handaxl it HONDA XL400R-500R © CRANKCASE BREATHER: Remove the plug from the drain tube to drain deposits. Install the drain plug. NOTE Service more frequently when ridden in ®SPARK PLUG Diseonneet the spark plug cap and remove the spark plug. ually inspect the spark plug electrodes for wear, The canter electrode should have a constant thickness. Discard the spark plug if the electrode is worn or if the insulator is cracked ‘or chipped. If the spark plug is in good condition and the deposits can be removed by sandblasting, the spark plug can be reused. Measure the gap with a wire gauge and adjust it, if necessary, by bending the side electrode. SPARK PLUG GAP: 0.6-0.7 mm (0.024—0.028 in) Check the spark plug seating washer and replace it with a new one if itis damaged. Install the washer on the spark plug and thread the plug into the head by hand to prevent cross-threading. After hand tightening, tighten the plug an additional 1/2 turn with spark plug wrench ta compress the washer. Connect the spark plug cap. RECOMMENDED SPARK PLUG Ee | XL500R — XL400R/XL500R, eos DRGES-L (NGK) or | DBEA (NGK) or X24ESR.U (ND) X24ES-U (ND) DR7ES (NGK) or | D7EA (NGK) or Standard For cold climat (Below 5°, 41°F) X226SR-U (ND) | X22ES-U (ND) For extended high DRSES (NGK) or | DSEA (NGK) or speed X27ESR-U(ND) | x27ES-U (ND) (1) SIDE ELECTRODE 0.6-07 mm (0.024-0.028 in) 22-13HONDs. XL400R-5001 XL400R-XL500R ADDENDUM ‘www.handaxt it (1) MANUAL DECOMPRESSOR CABLE STARTER DECOMPRESSOR mag es (XL500R ONLY) CAUTION | ‘Adjustment must be made for both Te ‘manual and kickstarter decompressor. NOTE + Adjust the decompressor linkage after adjusting the valve clearance, (See page 3-6) * Refer to page 38 for the XLAOOR starter decompressor adjustment, Loosen the manual decompresior cable lock ut and the adjusting nut to obtain slack Disconnect the manual decompressor cable at (2) ADJUSTING (3) LOCK NUT (4) LIFTER LEVER the dacompressor valve lifter lever. NUT (1) INDEX MARK Remove the crankshaft and timing mark hole z caps. Rotate the flywheel counterelockwise to align the T mark with the index mark, Make sure the piston is at TOC (Top Dead Genter) on the compression stroke. Measure the free play at the tip of the decompressor valve lifter fever FREE PLAY: 1-2mm (1/16 in) To adjust free play, loosen lock nut an kick starter decompressor cable and turn_adjusitna fiut.as equired, Tighten lock nut. TION | _ ew cessive free play causes hard starting insufficient free play may cause erratic idling and valve damage. Operate the kickstarter and check operation of the decom pressor mechanism. Recheck the free play. Reconnect the manually controlled decompres sor valve lifter cable, ‘Adjust manual lever free play by turning the adjusting nut. FREE PLAY: 5-8 mm (3/16-5/16 in) Tighten the lock nut and recheck free play. Install the fuel tank, seat, crankshaft and timing hole caps. Make sure that the decompressor cable does not interfere with handlebar rota- tion: (1) MANUAL DECOMPRESSOR LEVER 22-14XL400R-XL500R ADDENDUM www.handaxl it HOND: XL400R-500! DRIVE CHAIN Stop the engine and shift the transmission into neutral, Place the motorcycle on its side stand. Inspect the drive chain stack midway between the sprockets on the lower chain run. Move the chain up and down by hand and ‘measure the amount of slack. DRIVE CHAIN SLACK: 30-40 mm (1-1/4 1-5/8 in) Adjust as follows: Loosen the rear axle nut. Turn both right and left adjusters equally to Inerease or deerease chain slack. ‘After adjusting, be sure the same adjustment index mark number aligns with the stopper pins ‘on both side of the swingarm. Tighten the rear axie nut. TORQUE: 80-110 N-m (6.0-11.0 kg-m, 58-80 feb) Recheck the drive chai vwiheel rotation, free play and tree Check brake pedal free play and adjust, if necessary. chain and sprocket inspection: Replace the drive chain when the red zone on. the label aligns with the center of the stopper pin after the chain has been adjusted to 20—-30ennh (1-1/4—1-5/8 in) slack, Replacement chain: DID 520VS (DAIDO) or RKS20S0 (TAKASAGO} 100 Links : XLS0OR 102 Links : XL400R 30-40 mm (1-1/4-1-5/8 in) (1) AXLE_NUT (2) RED ZONE 22-15HOND: ©) xx200R-5001 XL400R-XL500 ADDENDUM www.handax! it (1) DRIVE CHAIN Inspect the drive chain and sprockets for damage or wear, A drive chain with damaged rollers, loose pins, or missing O-ring must be replaced, Replace any sprocket which is damaged or excessively worn. NOTE iew drive chain on worn sprockets or 8 worn chain on eG| sprockets. Both chain and sprockets must be in good condition or the replacement chai sprockets will wear rapidh (2) DRIVE SPROCKET (1) CHAIN SLIDER ‘Check the chain slider for wear. CAUTION If the chain slider becomes worn 30 that the swingarm is exposed, the chain will wear against the swingarm, Inspect the chain guide slider and replace if the depth of the chain groove is greater than specified. SERVICE LIMIT: 15 mm (0.6 in) ] (2) CHAIN GUIDE SLIDER (2) CHAIN GUIDE SLIDER @ FRONT BRAKE ‘Measure the front brake lever free play at the tip of the brake lever. BRAKE LEVER FREE PLAY: 20-30 mm (3/4 = 1-1/4 in) 22-16XL400R*XL500R ADDENDUM HONDsz ‘www.handaxl it € KL400R-5001 Perform minor adjustments with the upper adjuster on the handlebar. Adjust the free play by loosening the lock nut and turning the upper adjuster. Turn the upper adjuster in direction A to inerease free play. Turn the upper adjuster in direction B to decrease free play. Tighten the lock nut. Perform mejor adjustments with the lower adjuster on the brake panel Loosen the fornt brake cable guide bolts Adjust the free play by loosening the lock nut and turning the lower adjuster Turn the tower adjuster in direction A to increase free play. Turn the lower adjuster in direction B to decrease free play. CAUTION The front brake is equipped with the two leading shoe system. Do not attempt to remove the adjusting rod, Tighten the lock nut and cable guide bolts @ REAR BRAKE Brake pedal heigh NOTE The pedal height can be adjusted for the rider's preference. Adjust the brake pedal free play after pedal height adjustment. Loosen the lock nut and adjust the brake pedal height by turning the stopper bolt Tighten the lock nut securely, Adjust the brake pedal free play, (1) UPPER ADJUSTER, (2) Lock NUT (2) LOWER ADJUSTER Ny te (1) LOCK NUT 22-17XL400R"XL500R ADDENDUM HOND. XL400R- 5001 ‘Brake pedal free pl Measure the rear brake pedal free play. BRAKE PEDAL FREE PLAY: ‘20-30 mm (3/4 — 1-1/4 in) Adjust the free play by turning the adjuster, ‘Turn the adjuster in direction A to increase free play. Turn the adjuster in direetion B to decrease free play. © SUSPENSION Re Gheck the operation of the rear suspension and the entire suspension assembly. Be sure it is securely mounted and not damage or leaking Place the motorcycle on a support to raise the ‘ear wheel off the ground. Move the rear wheel sideways. forcefully. to check the swingarm bearings for wear. Forcefully move the check the suspension wheel vertically to kage bushings for wear, Replace bearings or bushings if excessively Tighten all bolts and nuts to the specified torque. () ADJUSTER 22-18XL400R-XL500R ADDENDUM HONDA ‘www.hondaxt it XL400R-500R © WHEEL/SPOKES NOTE Tire pressure should be check when the tires LO. SPECIFICATIONS Front | 180 KF Up to 90 kg (1.5 ko/em? 21 psi) (200 tos toad] | 150 ka P8115 kglom?, 21 psi) 180 kPa | Uptovehice O° (1.5 kolem*, 21 capacity load Re 175 kPa eat 1175 kg/em?, 24 psi) | Vehicle capacity toad! 150 kg (330 Ibs) | YoKO- | ¥989 Tye. | HAMA | ¥969 Brand} GPa INOUE tos = GPS " 3,00-21—4PR pens 4.60—-17—-4PR Check the tires for cuts, imbedded nails, or ‘other sharp. Tighten the wheel spokes. periodically. More frequent inspection is necessary when riding off-road. TORQUE: 25-50 kg-cm (29-57 inlb) Check the tightness of the rim lack. TORQUE: 10-15 N-m (1.0-1.5 kgm, 7-11 Feb} (07701-0020300) 22-19HONDA XL400R-XL500R ADDENDUM ‘www hondaxl.it XL400R-500R FUEL SYSTEM CARBURETOR SPECIFICATIONS ITEM XLS00R, - XL400R Venturi diameter 32.mm (1.26 in) 30. mm (1.18 in) Identification number PO78A, PO75A Float level 48.0 mm (0.71 in), —_—— Pilot screw opening [a ——— [Hate speed 1,200 £ 100 min“ (rpm), ————— Main jot “#30. #125 Throttle valve diameter 34 mm (1.34 in) 28 mm (1.10 in) Slow jet #55 #48 Throttle grip free play 2-6 mm {1/8—1/4 in) —— 0.10-0.25 ce/stroke —— ing pressure 380-430 mmHg =—— 3rd groove (from top) ——— CARBURETOR DISASSEMBLY NOTE the float chamber serew. (1) Tor COVER 2 (2) THROTTLE STOP SCREW of “ feo sev. 6) net NEEDLE SET (6) ah SCREW (4) THROTTLE VALVE (7) FLOAT 22-20 ae MAIN i" (12) FLOAT (13) ACCELERATOR PUMP, eS CHAMBER Ned ays VALVE (10) AIR mice n 1) FLOAT VALVE -HOND XL400R:XL500R ADDENDUM XL400R-500) www.hondax! it (1) DIAPHRAGM (2) SPRING ® ACCELERATOR PUMP DISASSEMBLY = Remove the accalerator pump caver and spring. (3) COVER (1) ROD Remove the diaphragm. Inspect the diaphragm for cracks and brittle- ness, NOTE Be sure the rod is not * CARBURETOR JETS REMOVAL Remove the float chamber body. Remove the float arm pin using @ needle nose pliers, Remove the float and float valve, € The pilot screws are factory pre-set and should not be removed unless the carbure- tor is overhauled. 22-21HOND= XL400R-5001 XL400R-XL500R ADDENDUM www.handaxlit (1) FLOAT VALVE Inspect the float vaive and seat for deposits, grooves or other damage, (4) NEEDLE JET HOLDER (3) MAIN JET Remove the main jet. Remove the needle jet holder and needle jet from the carburetor body, Remove the slow jet. Turn the pilot screw in and carefully count ‘the number of turns before it seats lightly, Make a note of this to use as a reference when reinstalling the pilot screw. [eaurio Damage to the pilot serew seat will occur if the pilot screw is tightened against the ‘seat, Remove the pilot serew. Inspect the pilot screw and replace if worn or damaged. (2) SLOW JET (1) PILOT SCREW lean the passages and jets with compressed air 22-22XL400R-XL500R ADDENDUM www.hondaxl.it Install the jets in the carburetor body. Install the pilot screw and return it to its original position as noted during removal Perform pilot serow adjustment if a new pilot screw is installed (page 22:24), ®@ ACCELERATOR PUMP ADJUSTMENT Lébséh the throttle atop screw, so the throttle valve is closed. Measure the clesrance between the accelerator pump rod and the adjusting arm with the throttle valye‘Closed. CREARANCE: 0-0.5 mm (0-0.002 in) “Adiust by bending the adjusting arm, ‘Adjust the idle speed @ FLOAT LEVEL INSPECTION Remove the float chamber ‘Measure the float level with the float tip just contacting the float valve and the carburetor inclined 15°—45" from vertical FLOAT LEVEL: | 18.0 mm (0.71 in) Replace the float if the float level is not within the specification. HOND1 © XL40OR-500 (7) WASHER (1) NEEDLE (4) SLOW JET JET (3) O-RING f (3) MAIN JET (2) NEEDLE JET HOLDER (1) ADJUSTING ARM (5) PILOT SCREW (6) SPRII 0-05 mm (00,02 in) Se (1) FLOAT LEVEL GAUGE (07401-0010000) 22-23HOND: XL400R-XL500R ADDENDUM XL400R-500 www.handaxl.it (1) THROTTLE STOP SCREW PILOT SCREW ADJUSTMENT (IDLE DROP PROCEDURE} CAUTION Damage to the pilot screw seat wild occur if the pilot serew is tightened against the seat. 1. Turn the pilot screw clockwise until it seats lightly and back it out to the specification, This is an initial setting prior to the final pilot screw adjustment, INITIAL PILOT SCREW OPENING: 2.1/4 Turns 2, Warm the engine up 10 operating tempara- ure. Stop and go driving for ten minutes is sufficient. 3 Stop the engine and connect a tachometer, 4 Start the engine and adjust the idle speed ‘with the throttle stop serew. IDLE SPEED: 1,200 + 100 min" (rpm) 5. Turn the pilot screw clockwise slowly until ‘the engine stops, and then back it out 2 turns. Start the engine ard readjust the idle speed with the throttle stop serew, if neces- ary. (1) PILOT SCREW. (1) Lock NUT. (2) ADJUSTING SCREW @ FAST IDLE SPEED ADJUSTMENT z ss Check the fast idte speed adjustment with the engine warm, and the choke knob in its detent position. FAST IDLE SPEED: 2,000-2,500 min” (rpm) To adjust, looten the lock nut and turn the adjusting bolt. Tighten the lock nut 22-24HONDA XL400R-XL500R ADDENDUM ‘www hondaxlit XL400R-500F CYLINDER HEAD (1) Bm BLOTS 10-14 Nem (1.0—1.4 kg-m, 7-10 ft-lb) (2) 7mm BOLT 3 13-17 Nm ’ (1.3-1.7 kgm, 9-12 ftlb) 10-14 Nom (1.0—1.4 ko-m, 7-10 feb) 15-18. N.m (1.51.8 ko-m, 11=13 feb) 17-23.N.m (1.7-2.3k9m, 12-17 feb) 10-14 Nm. (1.0=1.4 kg-m, 710 fb) (1.52.0 kg-m, 11=14 feb) 22-28 N.m (22-28 kgm, 16=20 ftlb) 22-25HONDz XL400R-5001 XL400R-XL500R ADDENDUM www.handax! it (1) 7mm BOLTS CYLINDER HEAD COVER REMOVAL Remove the engine from the frame (See Section 5). Loosen the decompresior cable lock nut and remove the cable from the holder. Disconnect the cable from the valve lifter lever. Remove the valve adjuster covers. Remove the cylinder head cover bolts nothing the location of the 7mm bolts Remove the cylinder head cover. (2) CYLINDER HEAD COVER (1) INDEX MA CAM SPROCKET INSTALLATION Coat the camshafr journals with molybdenum disulfide grease. Route the camshaft through the eam chain. Install the cam sprocket on the camshaft. NOTE Install the cam sprocket 20 that the timing marks face inside Turn the crankshaft and align the ""T" mark on the generator rotor with the index mark on the left crankease cover. Align the timing marks on the cam sprocket with the top of the cylinder head. (2) TIMING MARK 22-26HONDA XL400R-500R xLaool L500R ADDENDUM ‘www.handax! it Pull up the tensioner wedge with a priers white ; aan pushing in the stopper wedge as shown to er eeNsion 2 Toosen the tensioner insorta pin into the hole in the tensioner wedge to hold the tensioner in this position. | (@ stoPpeR Install the eam sprocket on the camshaft. (2) PIN Tighten the cam sprocket bolts. TORQUE: 17-23 N.m (1.7-2.3 kom , 12-17 Fb) (1) STOPPER WEDGE Recheck the valve timing alignment + Align the T mark on the flywheel with the index mark on the AC generator cover and ‘make sure that the timing marks on the eam sprocket are flush with the cylinder head upper surface. NOTE = Turn the camshaft until its cam lobes face bottom and install the eylinder head cover. Remove the pin from the tensioner wedge. Recheck tension of the cam chain tensioner by pushing in the stopper wedge. Pour fresh oil into the cylinder head until the ‘cams are submerged in the of 22-27HONDA XL400R-XL500R ADDENDUM www handaxl.it XL400R-500R (1) 7 mm BOLT. © CYLINDER HEAD COVER INSTALLATION Apply liquid sealer to the eylinder head mating surfaces of the eylinder head cover (See page 621), Install the eylinder head cover Tighten the cylinder head bolts to the specified torque, ' TORQUE: 6mm bolt: 10°14 N-m (1.01.4 kgm, 7-10 fb) Jmm bolt: 13—17N.m (1.3-1.7 kgm, 9-12 fetby NOTE * Tighten the head bolts in a crisscross pattern in two or more steps. +, Clean excessive sealent from the head. (2) CYLINDER HEAD COVER 1 (Check the valve clearance (page 3-6). (1) O-RING Install the valve adjuster covers. NOTE Make sure the O-ring is properly seated in the groove. Connect the decompression cable. Adjust the starter decompressor (page 22-14), (2) VALVE ADJUSTER COVER 22-28XL400R-XL500R ADDENDUM www.handax! it = CLUTCH/OIL. PUMP * 45-60 N.m © (456.0 kgm, 33-43 fib) “45-00Nm (4.5-6:0 ke-m, 33-43 -fr-ib) 8-12N.m Fe (0.81.2 kom, 6-9 ft-lb)XL400R+XL500R ADDENDUM www hondaxlit eC XL400R-5001 © CLUTCH SPRING SPECIFICATIONS 44.1 mm (1.74 in) 42.5 mm (1.67 in) 5 SSS STANDARD SERVICE LIMIT Clutch sprog ree length | oun ring prloadength 23,7—26.3 kg/27 mm (1) CLUTCH CENTER HOLDER — (2) PULSE GENERATO (079234260000) ROTO ®PULSE GENERATOR ROTOR Removal: Drain the engine oil from the crankease, Remove the clutch lifter plate and elutch spring (See page 8-6), Attach the cluteh center holder to the pressure plate with two clatch bolts Remove the primary gear lock nut. Remove the oil prossure pad and spring by removing the stopper pin. Remove the pulse generator rotor from the crankshaft. (2) OIL PRESSURE PAD 22-30XL400R-XL500R ADDENDUM Installation: Install the pulse generator rotor, aligning the dowel pin on the crankshaft with rotor cutout. Install the oll pressure pad, spring and stopper Pin. Tighten the primary gear tock nut to the specified torque. TORQUE: 45-60 N-m (4.5-6.0 kam, 33-43 fib) Check the oil pressure pad for smooth move- ment. Rotate the clutch lever to align the hole in the lever with the hole in the clutch cover and ingert the lifter piece, Install the right crankcase caver with new gasket (See page 8-16). Fill crankcase with recommended oil (See Page 2211, 2.3) HOND= XL400R- 5001 www.handaxl it (3) PULSE GENERATOR ROTOR (1) CLUTCH CENTER HOLDER (079234280000) 22-31HOND:. XL400R-XL500R ADDENDUM XL400R-506 www.handaxl.it AC GENERATOR 8-12 Nm (0.81.2 ko-m, 6-9 feb) y ee 100-120'N. m 9-13N.m (10.0=12.0 kg-m, (0.9-1.3 kom, 7-9 ftlb) 72-87 ft-lb) 8=12N.m (0.8-1.2 kon 6-9 ftib) 30-40. N.m (3.04.0 kg-m, 22-29 ft-lb) 8-12.N.m (0.81.2 kg-m, 6-0 fb) 22-32HOND: XL400R-500 XL400R-XL500R ADDENDUM honda (1) WIRE HOLDER BOLT (2) STATOR COL (3) STATOR COIL BAS AC GENERATOR STATOR COIL > Remow Remove the left erankease cover, Remove the AG generator wire holder bott and Ili stator coil bolts. Remove the stator coil from the stator base. Remove the stator coil base by removing screws, (4) STATOR COIL BOLTS (1) GRoove Installation: i Install the stator coil base with the groove facing upward. Torque the srews TORQUE: 9-13N.m (0.9-1.3 kom, 7-9 fri} (2) STATOR COIL BASE Install the stator coll on the stator base and torque the bolts. TORQUE: 8-12 N.m (0.8-1.2 ko-m, 6-9 fet) Install the wire clamp as shown. Inctall the loft crankcase cover (See page 9-4). (1) WIRE CLAMP (2) STATOR GOIL (3) BOLTS 22-33' XL400R-XL500R ADDENDUM HONDA XL400R-500R www.handaxl.it FRONT WHEEL /BRAKE /SUSPENSION /STEERING 18-30 Nom (1.8-3.0 kg-m, 13-22 ft-ib) 50-80 Nm (6.0-8.0 kom, 96-58 ft-lb) 10-14 Nim (1.01.4 kom, 7-10 feb)DA XL400R + SO0R_ SUPPLEMENT =mON XL400R - 500R NACHTRAG XL400R-500R XL400R - SOOR APENDICE www.handaxl it SERVICE INFORMATION 22.36 TROUBLE SHOOTING 22.37 HEADLIGHT/INSTRUMENT 22.38 FRONT WHEEL 22.30 FRONT BRAKE 22.82 FRONT FORK 22.45 STEERING STEM 22.53 ROUE/FREIN/SUSPENSION/ | VORDERRAD/BREMSE/ RUEDA/FRENO/SUSPEN- DIRECTION AVANT AUFHANGUNG/LENKUNG SION DIRECCION ——— DERANTERA INFORAMTION WARTUNGSINFORMA. * D'ENTRETIEN TIONEN 22.96 || [INFORMACION DE DEPISTAGE DES PANNES STORUNGSAESEITIGUNG 22.37 ||| SEFVICIO ae LOCALIZACION DE PHARE/INSTRUMENT SCHEINWERFER/ g a INSTRUMENT 22.8. ||| AVERIAS Aa Se emai poag ||| FARO/INSTRUMENTO 2238 RUEDADELANTERA 2239 ee re VORDERRADBREMSE 22-42 FRENODELANTERO = 2242 HORQUILLA DELANTERA 2245 VASTAGO DE DIREC: CION 22:53 VORDERRADGABEL «22-45 STEUERKOPFSCHAFT 22-63 TIGE DE DIRECTION 22-35XL400R-XL500R ADDENDUM www.hondaxt it SERVICE INFORMATION ® GENERAL INSTRUCTIONS Brake dust may contain asbestos which can be harmful 10 your health, Do not use compressed air To clean the brake drum or brake panel. Use a vacium with a sealed dust collector. Wear a protective face mask and thoroughly wash your hands when finished. Specia! 6 mm hex wrench 07917~3230000 Gireip priars 79143230001 Steering stem socket 07916-3710100 Bearing race remover 07953-MA00000 Steering stem 07946~4300101 Fork seal driver 079473710101 Common 0716-0020400 07716~-0020500 Attachment, 32% 36 mm 07746-0010100 Pilot, 15 mm 07748-0040300 ‘Attachment, 42 x 47 mm 07746-0010300 or Attachment 07946-4300200 Driver 0749-00100 © SPECIFICATIONS { ITEM STANDARD SERVICE LIMIT [Aste runout 0.2 mn (0.01 ind | ; 2.0 mm (0.08 in} Weer runout — 9mm {0-08 iol Baked i 730.0 mm (6.12 in) 131.0 mm (5.16 in} Brake shoe thicleness 4.00 mm (0.16 in) 2.0 mm (0.08 ind [Cerone tore pring aa 580.4 mim (2285 Fork tube runout = — Front fork air pressure 0-20 kPa (0=0.2 kalem®, 0-2. pall Capacity 376,0-381.0 cc (12.71-12.8 on) Pep ope [Level "163.0 mm (6.42 in} © TORQUE VALUES Steering stem nut + 80-120 N.m (8.0-12.0 kgm, 58-87 trib) Steering adjusting nut + 1-2.N.m (0,1-0.2 kg-m, 0.7—1.5 feb) Fork pinch bolt (upper) 18-23 N.m (1,8-2.3 kam, 13-17 feeb) Hower) 30-35 N.m (3.0-3.5 kg-m, 22-26 feb) Handlebar holder bolt 18-30 Nim (1.8-3.0 kgm, 19-22 frlb) Axle + 50-80 Nim (5.0-8.0 kg-m, 36-58 fe-b) Axle holder nut 2 10-14.N.m (1.0-1.4 kam, 7—10 ftlb) Steering stem pipe pinch bolt 40-60 Nim (4.06.0 kgm, 29-36 ft-lb) Brake arm bolt (upper arm) + B12N.m (0,8—1.2 kom, 6-9 ft-lb} flower arm) 10-14 Num (1.0-1.4 kgm, 710 ft-lb) 22-36XL400R-XL500R ADDENDUM www.handax! it HONDA XL400R-500R TROUBLE SHOOTING Hard steering 1, Steering stem nut too tight 2. Faulty steering stem bearings 3, Damaged steering stem bearings. 4, Insufficient tire pressure ‘Steers to one side or does not track straight 1, Bent front forks 2. Bent front axle, wheel ir talled incorrectly Front wheel wobbling 1. Distorted rim 2, Worn front wheel bearing 3, Faulty tire 4. Axle not tightened properly 5, Loose, bent or broken spokes Sofft suspension 4. Weak fork spring 2, Insutficient fluid weight in front forks 3. Incorrect fork air pressure Hard suspension 1. Incorrect fluid weight in front forks 2. Incorrect fork air pressure 3. Fork tube bent Front suspension noise 1, Slider binding 2. Insutficient fluid in forks 3. Loose front fork fasteners {Improper brake performance 1. Incorrect adjustment of lever 2. Brake shoes worn 3. Brake shoes contaminated 4. Brake cam worn 5. Brake drum worn 6, Brake arm serrations improperly engoted 7. Cam contacting area of shoes worn 22-37HONDA XL400R-500R XL400R+XL500R ADDENDUM www.handax! it @ HEADLIGHT/INSTRUMENT Removal: Remave the headlight case mounting bolts. Remove the headlight case, Remove the headlight by removing two mount ing bolts Remove the coupler box cover. Disconnect the instrument wires. (2) COUPLER (3) HEADLIGHT BOX COVER Discanneet the speedometer and tachometer cables from the instrument. Remove the speedometer and tachometer by removing mounting nuts. Installation: Install the instrument in the reverce order of removal. a (1) MOUNTING NUTS 22-38HONDA XL400R-XL500R ADDENDUM ww hondaxtit XL400R-5008 (1) FRONT BRAKE CABLE © FRONT WHEEL 2 e v Raise the front whee! off the ground by placing 2 block or safety stand under the engine. Disconnect the front brake cable fram the brake panel Disconnect the speedometer cable. Loosen the lower axle holder nuts then loosen the upper axle holder nuts, Unscrew the axle, and remove the frant wheel, CA Ter the brake panel fall. + Uf the brakes are not going to be serviced, do not turn the brake arm or arm con- necting rod. The rod synehronization will be off and stopping power will be re- duced, Disassembly: Remove the- dust seal and speedometer gear retainer from the wheel hub, Remove the bearings and collar from wheel hub, NOTE “If bearings are removed, replace them with ew bearings during assembly. (2) DUST SEAL 22-39 fHOND. XL400R*XL500R ADDENDUM XL400R- 5001 www.handax! it Assembly (1) DUST SEAL (4) DISTANCE COLLAR (5) BEARING (3) BEARING (1) DRIVER {07749-0010000) Pack all front wheel bearing cavities with crease, (Drive ithe right bearing first, ind drive in the left Install the distance col bearing HOTEL aes su svautene set! [i= + Do not allow the bearing to tilt while driving it in, + Install the bearings with the sealed end facing out, Avoid getting grease on the inside face of the Brake drum. (2) ATTACHMENT, 32 x 35 mm (07746-0010100) ANI PILOT, 15 mm (00746-0040300) 22-40HOND: XLA00R-XL500R ADDENDUM honda XL400R-5001 ‘Apply grease to the inside of the dust seal, Install the dust seal and the speedometer gear retainer, < (2) DUST SEAL (1) Boss Installation: Install the brake panel into the front wheel ‘Align the brake panel groove with the front fork slider boss, (2) GROOVE (y) TABS Aligning the lugs on the speedometer gear box with the tabs on the wheel hub, Install the speedometer gearbox into the wheel hub, (2) Lugs 22-41XL400R-XL500R ADDENDUM www.handaxl it HOND=s XL400R- 5001 Insert the axle through the wheel hub and thread it into the left fork leg. Then tighten the axle, TORQUE: 50-80.N-m (6.08.0 kg-m, 36-58 ftib) NOTE Make sure that the lug on the speedom: gearbox janed with tab on the fork leg. Install the axle holder with the “UP” mark facing upward. With the front brake applied, pump the front fork up and down several times, Tighten the upper holder nuts first, then tighten the lower holder nuts. TORQUE: 10-14 N-m (1.0-1.4 kgm, 7—10 feb) Connect the front brake and speedometer cables. Adjust the front brake lever free play (Page 22-16). FRONT BRAKE sssembly: Remove the front wheel Remove the front brake panel assembly from tho whae! hub, (CAUTION ‘© Mark the shoes to indicate the normal positions before disassembly. + Always replace the brake shoes in pairs. Remove the brake shoos and springs. Do not remove the brake arm rod when the brake shoes are replaced. (3) AXLE (1) AXLE (2) SPEEDOMETER CABLE (3) HOLDER NUTS _UPPE} (2) BRAKE SHOES 22-42HOND2 XL400R-500 XL400R-XL500R ADDENDUM ‘www.hendaxl it (1) BOLT (2) BRAKE ARM (3) BOLT Remove the bolts atta ‘the brake cams. ‘each brake arm to Remove the brake arms with the arm connect ing rod. Do not try to turn the connecting rod when removing the brake arms of syn- chrontzation of the brake arms will be out of order and stopping power will be re- duced. Remove the brake cams from the brake panel, ‘Aeon: (4) CONNECTING ROD (5) BRAKE ARM (1) BRAKE SHOES (2) BRAKE CAMS. (4) DUST SEALS (3) SEAT WASHER (5) RETURN SPRING (6) INDICATOR PLAT (6) INDICATOR ‘Assemble the brake shoes and brake arms into PLATE the brake panel as shown iS (4) BUST SEAL {huzton, = Ls (7) WASHER |= tnstall original shoes and. Brake came in their original positions. Ly * Apply grease to the sliding surfuces of i the brake came i a a a (2) BRAKE CAM Contaminated brake linings reduce stop- ing power. Keep grease off the linings. (3) SEAT WASHER 22-43XL400R-XL500R ADDENDUM Install the brake arm assembly on the brake cams. NOTE When installing the brake arm, align the ‘punch marks on each brake arm and brake [carrion] _ = Be carefull to do not turn the arms and connecting rod during installation, Tighten the brake arm bolts TORQUE: Upper arm: 812 Nem (0.8-1.2 kg-m, 6-9 ft-lb) Lower arm: 10—14N-m {1,0-1.4 kg-m, 7-101 ‘Visually inspect the brake cam synchronization bby operating the brake arm. ‘Adjust the brake cam eynchronization if neces: sary. Adjustment: Adjust the brake arm connceting rod whenever the cam, arm or connecting rod are replaced. While pushing the brake shoes in toware one another by hand to remove any cleerance between the shoes and brake cams, loosen the brake arm connecting rod lock nut, turn the rod until it shows free play, and then turn the fod in direction A just enough to remove that free play. NOTE Tighten the lock nut. Make sure that both brake cams are parallel to gach other and that arms upper and lower start to move at the same time when the brake is applied. ‘You are looking for the point that free play is just removed, ‘www.handaxl.it (1) LOWER ARM BOLT (4) PUNCH MARKS. (1) BRAKE CAM (a) LOCK NUT HONDA XL400R-500R (2) UPPER ARM BOLT (4) LOWER BRAKE ARM 22-44HONDA XL400R-XL500R ADDENDUM XL400R-500R ‘© FRONT FORK Remove the front wheel, Loosen the fork boot clamp screws. Remove the speedometer cable from the clamp, ‘on the right fork. (2) SPEEDOMETER CABLE CLAMP (1) FORK PINCH BOLTS Loosen the upper and lower fork pinch bolts. Remove the front forks, Remove the fork boot, (1) AIR VALVE (2) FORK CAP BOLT Disassembly: Release the air from each fork tube by pressing the air valve core, Be sure t0 release front fork ait pressure before disassembling £0 prevent parts from becoming projectiles. Hold the tube in a vise with soft jaws or a shop towel, avoiding the sliding surface. Remove the fork cap bolt. TIA The cap bolts are under spring pressure, Use care when removing and wear eve and face protection. at am 22-45HONDA XL400R-XL5Q0R ADDENDUM ‘www hondaxtit XL400R-S00R ~ (1) SPACER (2) FORK SPRING Remove the specer, seat washer and fork spring from the fork tube, (3) SEAT WASHER Pour out any remaining fork fluid by pumping the fork several times, Hold the fork slider in a vise with soft jaws or @ shop towel and hold the fork piston with a holder. Remove the hex bolt, (CAUTION Dorrit distort the fork sider ina vibe. 22-46XL400R-XL500R ADDENDUM www. hondaxlit XL400R-SO0R Pull the fork tube out of the slider. Remove the fork piston from the fork tube. Remove the oil lock piece from the fork Remove the dust seal using a screwdriver with a dull or rounded edge. NOTE + Avoid damage the inner and outer sur- faces of the fork slider when removing ‘the oil seal, + If the dust seal is removed, replace it with new one. ‘with snap-ring pliers. (1) FORK SLIDER (2) FORK TUBE (1) DUST SEAL. (1) CIRCLIP (2) CIRCLIP PLIERS (07914-3230001) —————— ee 22-47XL400R-XL500R ADDENDUM ‘www hondaxlit XL400R-S00R Remove the oil seal using a screwdriver with a ‘dull or rounded eige, NOTE + Avoid damaging the inner and outer sur- faces of the fork slider when removing the oil sea, * The oil seal must be, replaced with new: seal during assembly, Remove the back-up ring. () OIL SEAL i ion: Sa (1) FORK SLIDER (2) FORK TUBE Check the fork tube, fork slider, piston and oll lock piece for score marks, scratches, or exces- sive oF abnormal wear. (3) PISTON RING (4) O1L, f tock piece) (5) FORK PISTON Replace any damaged or badly worn parts. ‘Check the fork piston ring for wear or damage, ‘Check the rebound spring for fatigue or damage. Measure the fork spring free length, SERVICE LIMIT: 568.8 mm (22.39 in) 22-48. HONDA XL400R-XL500R ADDENDUM ‘www hondaxl it XL4O0R-500R Assembly: ‘Clean all parts with non-flammable or high flash point solvent and wipe them off throughly before assembly. (1) AIR VALVE Cans rei eae TUBE (1) FORK BOOTS s S wa Ga Cour (16) FORK SLIDER (17) DRAIN BOLT (5) FORK SPRING (6) PISTON RING (7), REBOUND ‘SPRING (10) OIL Lock PIECE (14) OIL SEAL, (18) BACK-UP RING. (8) FORK PISTON (18) SOCKET BOLT (1) FORK PISTON (2) FORK SLIDER Install the fork piston and rebound spring into the fork tube from top. Place the oil lock piece on the end of the piston, Insert the fork tube into the stider. (3) FORK TUBE — (4) OIL LOCK PIECE 22-49XL400R-XL500R ADDENDUM Apply a locking agent to the socket bolt threads and underside of the bolt and torque the bolt. TORQUE: 15-25 N-m (1.5-2.5 kgm, 11-18 fb) (CAUTION. Excessive vise pressure can damage the fork slider. NOTE Temporarily install the spring, spacer and fork bolt if difficulty is encountered in moving the socket bolt. Install the back-up ring. Coat 2 new oil seal with ATF and install it with ‘the seal markings facing up. Drive the seal in with the seal driver, Install the eirclip into groove of the stider with sharp edge facing upward, www hondaxt it (1) 6mm HEX WRENCH (07917-3230000) (1) OIL, SEAL [sar (2) BACK-UP RING (3) FORK SEAL DRIVER (07947-3710101) (1) CIRCLIP. PLIERS (07914-3230001) (2) CIRCLIP 22-50XL400R*XL500R ADDENDUM HONDA XL400R-500R www.hondax! it Install the dust seal with the seal markings facing down and drive the seal in with the seal driver. Pour in the specified amount of ATF. CAPACITY: 376,0-381,0 ce (12.71-12.88 02) Compress the front fork all the way and measure the oil level from the top of the tube, NOTE Be sure the oil level is the some in both fork tubes. STANDARD OIL LEVEL: 163.0 mm (6.42 in) Wipe all olf from the fork spring and install it into the fork tube with: the. narrow’ colle facing down. Install the spring seat washer and spacer and install the fork cap bolt. (CAUTION Be careful not 10 erosethread the fork eap bolts Tighten the fork cap bolt. TORQUE: 15-30 Nem (1.5-3.0 kgm, 11-22 feb) Install the fork boat and boot clamp. NOTE Do not tighten the clamps until the forks are properly installed on the wt (1) DUST SEAL (2) CIRCLIP (3) FORK SEAL DRIVER (07947-710101) ) OIL LEVEL (2) O1L (1) FORK SPRING (3) FORK CAP BOLT (2) DOWN 22-51HONDA XL400R-XL500R ADDENDUM ‘www. hondaxlit XL400R-500R {nstallation: Install the fork tubes in the fork bridge and steering stem while rotating them by hand, ‘Align the top surface of fork tube with the top surface of the fork bridge, (1) FORK PINCH BOLTS Tighten the upper and lower fork pinch bolts, ToRaUt Upper; 18-23 Num (1.8=23 kom, 13-17 ftelb) Lower : 30-35 Nm (3.0-3.5 kg-m, 22-25 ft-lb) Bring the top of each fork boot into contact ‘with the steering stem and tighten the clamp. Install the speedometer cable in the clamps on the left fork slider. Install the front wheel (Page 22-41), Make sure all weight is off the front wheel, and charge the forks with air. STANDARD PRESSURE: 0-20 kPa (0-0.2 ka/em*, 0-28 pai) CAUTION] Use a low-volume low-pressure pump 10 charge the forks with atr, (2) SPEEDOMETER CABLE CLAMP 22-52HONDA XL400R-500R XL400R-XL500R ADDENDUM se whondaxie (1) HANDLEBAR © STEERING STEM isassomnbaly jove the instrument (Page 22-38). Remove the front wheel (Page 22-39), Remove the front fende Remove the hor bracket from the steering stem, Remove the handlebar. Loosen the upper fork pinch bolts, (2) UPPER FORK PINCH BOLTS (1) FORK BRIDGE (2) EXTENSION (07716-0020500) Remove the stem nut and remove the for bridge, Remove the front fork legs by loosening the lower fork pinch bolts. (3) SOCKET WRENCH, 30 x 32mm (07716-0020400) (1) STEERING STEM ADJUSTER NUT (2) UPPER BEARING Remove the steering stem adjuster nut, NOTE Hold the steering stem to prevent it from falling. Remove the steering stem, Remove the upper bearing. (3) STEERING STEM 22-53HONDA XL400R-XL500R ADDENDUM ‘wwwhondaxtit © XL400R-500R ‘Check the bearings for operation and replace if My) SEARING necessary, ‘Check the bearing races for wear or damage and replace if necessary, me i. (2) BEARING RACE (1) BEARING RACE REMOVER (07953-MA00000) Remove the bearing race with @ bearing race remover, Drive in the new races with @ steering race river, NOTE Drive the races in squarely until they seat. (2) ATTACHMENT (07746-0010300 or 07946-4300200) 22-54XLA400R+XL500R ADDENDUM www hondaxiit” XL400R-5OOR To remove the lower bearing, remove the steers ing stem pipe pinch bolt. Remove the lower bearing using a hydraulic press. NOTE ‘Set the blocks nea ing stom. center of the steer Install new dust seal Press the new bearing onto the stem pipe with, a hydraulic press and steering stem driver. Install and torque the steering stem pipe pinch bolt. TORQUE: 40-50 N-m (6.0-5.0 kgm, 29-36 feb) Installation: lean the races and apply grease to the bearings, Slide the steering stem through the steering head from the bottom, (1) STEM PIPE 42) LOWER BEARING (1) STEERING STEM DRIVER (07946-4300101 (2) LOWER BEARING (2) LOWER BEARING “eo (5) DUST COVER (@) bust sea." (1), BEARING RACE. SSy—-(6) Aduusrer S_ NUT (7) UPPER BEARING (8) BEARING RACE af 4 (4) STEERING STEM 22-55HONDA XL400R- 5005 www.hondaxt it (1) STEERING STEM SOCKET? (2) STEERING ADJUSTER (07916-3710100) XL400R-XL500R ADDENDUM Remove the dust cover from the steering ad- juster nut, Tighten the steering adjuster nut until the stem rotates freely, but without play, TORQUE: 1-2N-m (0.1-0.2 kgm, 0.7-1.5 ft-lb) Reinstall the dust cover on the steering adjuster nut, (3) DUST COVER (1)_EXTENSION (07716-0020500) Temporarily hold the front fork legs by tighten- ing the fork pinch bolts, Install the fork bridge onto the front fork tubes 4nd tirhgen the stem nut, TORQUE: 80-120 N-m (8.0-120 kg-m, 58-87 fe-1b) Loosen the lower pinch bolts. Then align the fork tube top surface with the upper edge of the fork bridge. Tighten upper and lower fork pinch bolts, 18-23 Nem (1.8-2.3 kgm, 19-17 feb} Lower: 30-35 N‘m Hit (3.0-35 ka-m, 22-25 fttb} nee oes (2) SOCKET WRENCH, 30 x 32 mm (07716-0020400) (1) PLASTIC GROMMET Install the plastic grommet in the steering stem E mut, Reinstall the remaining parts in reverse order of removal 22-56HOND: XL400R-XL500R ADDENDUM XL400R-500! REAR WHEEL /SUSPENSION www.handaxl.it 60-75 Nm (6.0-7.5 kom, 43-64 ft-lb) 60-75 N.m (6.0-7.6 km, 43-54 ft-lb) 70-100 N.m (7.0-10.0 kgt 51-72 fel 80-110. Nm Num B kgm, 43-54 Fell 70~100 N.m 90-120 (7.0-10,0 kg-m, 51-72 feb) 48.0-12.0 kg-m, 65-87 fe-lb) 38—48 N.m (3.84.8 kom, 27-35 fttb) 22-57XL400R - SOOR SUPPLEMENT sone XLA00R * 500R NACHTRAG XL400R-500R hondasie XLA00R * 500R APENDICE SERVICE INFORMATION 22:59 ] TROUBLESHOOTING 22-60 REAR WHEEL 22.61 REAR BRAKE 22-66 SHOCK ABSORBERS 22-66 SWINGARM 22.74 ROUE/FREIN/SUSPENSION HINTERRAD/BREMSE/ RUEDA/FRENO/ ARRIERE AUFHANGUNG SUSPENSION TRASERA INFORMATION WARTUNGSINFORMA INFORMACION DE D'ENTRETIEN 2259|| | TIONEN 22-59 ||| SERVICIO 2.59 DEPISTAGE DES PANNES 22-60|| | STORUNGSBESEITIGUNG 22-60 ||| LOCALIZACION DE AVERIAS 2260 ROUE ARRIERE 22-61||| HINTERRAD 22-61 FREIN ARRIERE 2266||| HINTERRADBREMSE 22.06 ||| RUEPATRASERA aa F AMORTISSEUR DE CHOC 22.66||| HINTERRAD- — ae BREMSSTOSSDAMPFER 27.66 ||| AMORTIGUADOR DE BRAS OSCILLANT een 2221 ||| CHOQUE 2266 BRAZO OSCILANTE nn 22-58HONDA XL400R-XL500R ADDENDUM Www hondaxtit XL400R-5008 SERVICE INFORMATION © GENERAL INSTRUCTIONS ~ Broke dust may contain asbestos which ean be harmful to your health. Do not wse compressed air to clean the brake drum or brake panel. Use a vacuum with o sealed dust collector. Wear a protective face mask and thoroughly wash ‘Your hands when finished. + Use only genuine rear suspension linkage and shock absorber pivot{mount bolts. Others may not have adeauate strength, Note the installation direction of the bolts. 07996-3710000 or Handle 07936-3710100 Weight 079363710200 Remover, 23 mm 0783637106000. 07946~KAS0000 TFT oat RaGT | or Retainer wrench 07910~3600000 07710~-0010201 Attachment, 37 x 40 mm 077460010200 07949-30000 Pilot, 17 mm 07746-04040 (073463000100 Attachment, 42 x 47 mm 07748-0010300 Pilot, 20 een 07746-0040500 Driver '07749-0010000 Optional Pin spanner 89201-KA4—810 Pin spanner 89202-KA4—B10 © SPECIFICATIONS i SERVICE LIMIT Fear shock absorber spring free length 248.5 mm (8.78 in) [Rear brake drum 1.0: [130.0 mmm (6.12 in) 131.0 mm (5.16 in) Rear brake lining thickness [4 rmm {0.16 in) 2mm (0.08 in) Reear shock absorber damper Sune ses 2-28 kg (62-84 Ib) 28 kg (62 Ib) ‘Swingarm pivot eenter collar 0.0. 19.987 = 20.000 mm | to-7a80— 0.7874" 19,915 mm (0.7840 in) © TORQUE VALUES Rear shock absorber mount bolt (upper) 60-7 N.m (6.07.5 ka-m, 43-84 ft-Ib) (ower) 38-48 Num (3,8~-4.8 kg-m, 27-35 ft-lb) Rear axle nut 80=110 Nim (8.0—11.0 kg-m, 58~-B0 ft-lb) Swingarm pivot bolt 70-100 N.m (7.0—10.0 kg-m, 5172 ft-lb) Shack arm pivot bolt (Swingarm side} 90-120 N.m (8.0-12.0 kg-m, 65-87 ft-lb) (Shock link side) 60-75 N.m (6.0-7.8 kg-m, 43-54 ft-lb) Shock link pivot bolt 60—75 N.m (6.07.5 kg-m, 4354 ft-lb) 22-59XL400R-XL500R ADDENDUM TROUBLESHOOTING Nobbie or Vibration in Motoreyele 1. Tire pressure incorrect, 2. Faulty tire &. Bent rim 4, Loose wheel bearing 5, Loose or bent spokes 6. Swingarm Bushing worn 7. Chain adjusters not adjusted equally Suspension Noise 1. Loose fasteners 2, Faulty rear damper 3. Worn suspension linkage pivot bushing www.hondaxl it Soft Suspension 1, Weak spring 2. Improper rear suspension spring preload adjusting Hard Suspension 1, Improper rear suspension pring preload ad- justing 2. Bent shack absorber rod. 3. Swingarm pivot bearings damaged. Poor Brake Performance 1. Improper brake adjustment 2. Worn brake shoes 3. Brake linings oily, greasy or dirty 4, Worn brake cam 5. Worn brake drum 6. Brake arm serrations improperly engaged 7. Brake shoes worn at cam contact area, 22-60HONDA XL400R-500R XL400R-XL500R ADDENDUM www.hondaxl it (1) BRAKE ROD REAR WHEEL Ps i Raise the rear wheel off the ground by placing a jack or block under the engine. Remove the rear brake adjuster nut and discon: rect the brake rod. (2) ADJUSTER NUT 1) STOPPER PIN (2) ADJUSTER Loosen the rear axle nut, oie i ‘Turn both adjusters zo the rear wheel can be moved all the way forward for maximum drive hain stock, Move the rear wheel forward snd “hook” the adjuster over the stopper pins on the swingarm, (3) REAR AXLE NUT (1) STOPPER PIN Derail the drive chain from the drive sprocket, Remove the stopper plate from the pin on the sswingarm’s right side, Remove the rear wheel with the rear axle. (2) STOPPER PLATE 22-61HONDA XL400R-XL500R ADDENDUM ww hondaxlit XL400R-500R Disassembly: (1) BEARING (2) COLLAR (3) DRIVEN FLANGE (4) BEARING (6) DUST SEAL 6 %@ ) (8) CIRCLIP @ Pe (7) SPROCKET (8) O-RING (9) BEARING — (10) RETAINER (1) RETAINER WRENCH ATTACHMENT (07710-0010200) Remove the bearing retainer, e i Remove the bearing and collar from the wheel hub. (2) RETAINER WRENCH BODY (07710-0010401) 22-62XL400R-XL500R ADDENDUM ‘www.handax! it (©) Srcon.soon : XL400R-500R Remove the dust seal and circlip, then remove tthe bearing from the driven flange. Assembly: Pack the bearing cavity with grease. Install the bearing with the sealed end facing Install the circlip. Grease the dust seal lip, Drive the dust seal into the driven flange. (2) BEARING (1)_DRIVER(07749-0010000) een (2) ATTACHMENT, 42 x 47 mm (07748-0010300) AND PILOT, 20 mm (07748-0040500) (1) DRIVER(07749-001 0000) (2) DUST SEAL 7 (3) ATTACHMENT 42x47 mm (07748-0010300) 22-63HONDA XL400R-500R XL400R-XL500R ADDENDUM www.handaxl it (1) DRIVER (07749-0010000) Pack the naw bearing cativities with grease. Drive ‘the left bearing in the hub first, then install the distance collar and drive in the right bearing, NOTE Install both bearings with the sealed end facing out, pa Grease on the brake linings reduces stop- 1g power. Keep grease off the linings. Kite 7 (2) ATTACHMENT, 37 x 40 mm (07746-0010200) AND PILOT, 17 mm (07746-0040400) Grease the bearing retainer and install it in the ee eee eee ee ae hub with the retainer wrench attachment and retainer wrench body | (2) RETAINER WRENCH BODY (07710.0010401) 22-64XL400R-XL500R ADDENDUM Installat Place the rear wheel into the swingarm locating the tang on the swingarm into the slot on the brake panel, Set the stopper plate to the pin on the swingarm, Run the chain over the final sprocket, Turn the right and left chain adjuster plates and ‘adjust the drive chain, (page 22-15). CAUTION] The same index mark on both sides should (align: with pins on the swingarm. Tighten the axle nut, TORQUE: 80—110N-m (B.0-11.0 kg-m, 58-80 feb) ‘Connect the rear brake rod, Adjust the rear brake pedal free play. www.handaxl.it (3) STOPPER (1) ADJUSTER (2) ADJUSTER NUT HONDA XLAOOR-500R (3) BRAKE ROD 22-65HOND# XL400R+XL500R ADDENDUM ‘www.hondax! it XL400R+5001 @ REAR BRAKE Measure the rear brake drum, SERVICE LIMIT: 131.0 mm (6.16 in) (1) BRAKE ARM (2) PUNCH MARKS Install the brake: arm aligning the punch mark with the punch mark on the: brake cam, ‘Torque the brake arm bolt, TORQUE: 8-12N-m (0.8-1.2 kg-m, 6~9 feb) Install the brake arm pin, Pface.e’new cotter pin through the brake arm pin and spread the ends. (3) COTTER (4) BRAKE PIN ARM PIN (1) MUD GUARD - my @ SHOCK ABSORBER Removal: Raise the rear wheel off the ground by placing a jack or workstand under the engine, Remove the right and left side covers. Remove the mud guard and the seat, 22-66XL400R-XL500R ADDENDUM ‘www.handaxl it HONDA XL400R-500R Remove the sheck link pivot bolt, Lassen tha shock arm pivot bolt (swing arm side}. Lossen the rear shock “absorber lower mount bolt. Lift up the rear wheel with a jack or block under the wheel, then remove the two bolts. Remove the shock arm with the shock link. Remove the rear shock absorber upper mount bolt and remove the shock absorber from behind. NOTE the shock absorber to prevent it from Do not swing the swingarm with no rear shock absorber installed. You may get hurt by the wheels or damage the swingarm, (1) PIVOT BOLT (1) LOWER MOUNT BOLT 22-67HONDA XL400R-XL500R ADDENDUM ‘wiww:hondaxl.ie XL400R-500R (1) PIN SPANNER A (89201-KA4-810) PIN SPANNER 8 (89202-KA4-810) ‘Dissszembty:: ma Hold the upper mount of the shock absorber in 1a vise with soft jaws or shop towel, Remove the lock nut and adjusting nut. NOTE “The pin spanners are optional tools. UTION 0 not try to disassembly the gar filed damper, Remove the spring. (1) NUT Hold the ower mount of the shock absorber in a vise with soft jawe or shop towel, ‘Turn the lock nut and remove the lower maunt. Remove the dust seal, spring quide, spring seat ‘and spring seat stopper. (2) LOWER MOUNT ae mi inspection: Measure the rear shack absorber spring length. SERVICE LIMIT: 248.5 mm (9.78in) 22-68HONDA XL400R-XL500R ADDENDUM ‘www hondaxlit XL400R-500R Visually inspect the damper unit for dents, oll leaks or other faults. Replace the damper unit if necessary, Place the damper rod on 2 scale and measure the foree required to compress the damper unit 10mm (0.4 in). COMPRESSION FORCE: 28-38 kg (62—84 Ib) If the required is less than 28 kg (62 Ib), gas is leaking. Examine the damper rod and replace the damper unit if bent or scored. Assombly: (2) LOCK NUT (3) ADJUSTING NUT SA 2 aa. Dust SEAL = (5) SPRING SEAT ey & Qo (6) SPRING GUIDE (1) DAMPER UNIT (7) SEAT STOPPER (8) LOWER MOUNT (9) SPRING 22-69HONDA XL400R-XL500R ADDENDUM www.hondaxlit XL400R-500R Install the dust seal and other parts. Apply a locking agent to the lower mount threads. Align the pin of spring seat stopper with the lower mount cut out and torque the nut. TORQUE: 60-75 N-m (6.0-7.5 kgm, 45-54 feb) (8) SPRING Measure the springs length, Turn the adjusting nut to obtain the standard spring length, STANDARD SPRING LENGTH: 241 mm (9.49 in) (1) ADJUSTING Tighten the lock nut a CAUTION A: SHORTEN THE SPRING LENGTH 5 Bi: INCREASE THE SPRING LENGTH | Do not ride the motorcycle without the Spring havireg preload, Loss of rider control could result, Inseallatios Apply molybdenum disulfied (MoS:) paste (containing more than 45% of MoS2) to the upper mount bushings, Use MoS: paste (containing more than | 45% of MoS: ) as follows: = Molykote® G-n Paste manufactured by Dow Corning U.S.A. + Locol Paste manufactured by Sumico Lubricant Co., LTO. Japan. + Other lubricants of equivalent quality. ‘Attach the shock absorber to the frame and torque the upper mount bolt. TORQUE: 60~75 N-m (6.0-7.5 kg-m, 43-54 feb) Lubricate the shock arm and shock link pivots with the MoS: poste (containing more than 45% of MoS:). Place the shock arm with the shock tink into the swingarm, Install the shock absorber lower mount bolt and torque the bolt, TORQUE: 36—48N-m (3.8-4,8 kg-m, 27-35 feb) Install the shock link pivot bolt (swingarm side). Torque the bolt TORQUE: 80-120 N-m (9.0-12.0 kgm, 65-87 fetb) (2) LOWER MOUNT BOLT 22-70XL400R-XL500R ADDENDUM ‘www.handax! it HONDA XL400R-500R Attach the shock Tink to the frame and torque the pivot bolt. TORQUE: 60-75 Nem (6.0-7.5 ko-m, 43-54 fttb) Install the mud guard. Install the right and left side covers, Install the seat. (Check the operation of the reer suspension. @ SWINGARM Removal: Raise the rear wheel off the ground with a jack co block under the engine. Remove the right and left side covers, Remove the rear wheel (page 22-61) Remove the shock link pivot bolt. Remove the mud guard. Remove the chain case. Remove the rear brake return spring, Remove the rear shock absorber lower mount bolt. ) PIVOT BOLT (1) PIVOT BOLT CASE (2) LOWER MOUNT BOLT (3) RETURN SPRING 22-71‘XL400R*XL500R ADDENDUM www.handax! it HONDA XLGOOR+SOOR Loosen the 12mm engine mount bolt. Remove the swingarm by removing the pivot bolt. Remove the shack arm from the swingarm, Remove the chain stider, chain guide, passenger foot peg and foot guard. Disassemble the shock arm from the shock link. Inspect the shock arm and shock link com- ponents for damage or excessive or abnormal ‘wear; replace if necessary, Lubricate the parts shown with molybdenum isulfied (MoS:) paste (See page 22-70). Remove the dust seals from the swingarm pivot holes. Inspect the bearings and thrust bearings for damage or excessive or abnormal wear and replace thern if necessary (page 22-73). (1) SHOCK ARM (3) CHAIN SLIDER (1) SHOCK. LINK (2) PIVOT BOLT (1) 12mm ENGINE MOUNT BOLT (2) FOOT GUARD. (4) PASSENGER FOOT PEG __(2) DUST SEAL 22-72XL400R+XL500R ADDENDUM www.hondax! it HONDA XL400R-500R Femave the dust covers. Install the bearing remover into the swingarm pivat hole and expand the tool behind the bearing. Drive the bearings out with the bearing remover. Assombly: Clean the bearings, the lubricate them with grease. Carefully drive the new bearings and thrust ‘bushings into the swingarm NOTE Install the beairngs with the marks facing out. Connect the shock link to the shock arm and torque the pivot bolt, TORQUE: 60-75 N-m (6.0-7.5 kg-m, 43-54 feb) Install the shock arm/link to the swingarm and torque the pivot bolt. TORQUE: 90-120 N-m (9.0-12.0 ko-m, 65-87 ft-lb) Install the chain slider, chain guide passenger footpegs and foot guard. Apply grease to the inside of the pivot dust seal. ~ (i) BEARING REMOVER (07938-3710600) (2) WEIGHT (07936-3710200) (@) BEARING (5) THRUST BUSHING (1) BEARING REMOVER (6) SWINGARM __ (07936-3710600) (1) SHOCK ARM (2) PIVOT BOLT (3) FOOT GUARD (5) PASSENGER FOOTPEG (4) CHAIN SLIDER (6) CHAIN GUID —— 22-73XL400R-XL500R ADDENDUM ‘www.handax! it HOND=2 XL400R-5001 Installation: Install the swingarm and torque the pivot bolt, TORQUE: 70-100 Nm (7.0-10.0 kg-m, 51—72 ft-lb) Torque the 12mm engine mount bolt. TORQUE: 90-100 N.m (8.0-10.0 kg-m, 65=72 ft-Ib) Check the swingarm operation, Antach the shock absorber lower mount on the shock arm and torque the mount bolt, TORQUE: 38-48 N.m (3.8-4.8 kg-m, 27-35 ft-lb) Install the shock link to the frame and torque the pivot bolt. TORQUE: 60-75 N.m (6.0-7.5 kam, 43-54 frlb) After installation, grease the swingarm pivot through the grease fitting, Grease the linkage bushings through the greste fittings with the molybdenum disulfide (MoS) paste (See page 22-70), Install the chain case, and mud guard. Install the rear wheel (page 22-65). Install the rear brake return spring and rear brake rod, (Check the operation of the rear suspension, (2) 12mm ENGINE MOUNT BOLT (1) PIVOT BOLT (1) LOWER MOUNT BOLT (3) GREASE FITTINGS (3) GREASE FITTINGS 22-74SOOR SUPPLEMENT HOND=s S00R NACHTRAG XL400R-XL500R ADDENDUM hondaxtit, °500R APENDICE XL400R-500F BATTERY /CHARGING SYSTEM (1) ACREGULATOR (2) yoLTaGE (3) BATTERY REGULATOR/RECTIFIER (4) ACGENERATOR 5 BATTERIE/CIRCUIT DE BATTERIE/LADESYSTEM BATERIA/SISTEMA DE CHARGE CARGA (0) WECHSELSTROMREGULATOR (@) REGULATEUR DE COURANT (2S ARRINGSRESUL ATOR 1) REGULADOR DE CA, ‘ALTERNATIF @ see (2) REGULADOR/RECTIFICADOR. (2) REGULATEUR/REDRESSEUR DE Ae ilceaaa oy DETENRION so (8) ALTERNADOR @) BATTERIE () ALTERNATEUR 22-75HONDA *LAGGR + SOUR, SUPPLEMENT, L400R + 500R XL400R-500R XL400R-XL500R: XLAOOR » 500K APENDICE, www.hondaxl.it YSTEM DIAGRAM (5) IGNITION SWITCH (6) FUSE 108 (7)BATTERY NER (8) METER ENERATOR MereR (2) AG REGULATOR = =|> = =F (4) VOLTAGE (3) HEADLIGHT REGULATOR/ (8) TAILLIGHT RECTIFIER (10) GERMANY, SWEDEN TYPE (18)_IGNITIONSWITCH (19) FUSE 108 (20) BATTERY Ld) tae =) eS = 47) A (1a) TAILLIGHT () Regutaton/ 11) AC GENERATOR (12) AGREGULATOR (13) HEADLIGHT (15) POSITION LIGHT RECTIFIER (16) METER LIGHT SCHEMA DE CABLAGE SYSTEMSCHALTPLAN DIAGRAMA DEL SISTEMA e (1) WEeHSELSTROMLICHTMA. G} REGULATEURDECA ScuINE {y) ALTERNADOR Boe BL ReuR SS RNEBUEATO | parc ci HEINWERFER 0 | RECUR UR RSOR ESSER DE (3). SPANNUNGSREGULATOR. (4) REGULADOR/RECTIFICADOR is GLEICHRICHTER 6 CONTACTEUR D'ALLUMAGE we Seeeaies (5) INTERRUPTOR OE ENGENDIDO (0) BATTERIE (6) SICHERUNG 104, (6) FUSIBLE 104 (@) FEU ARRIERE 0) aatrenle (7) BATERIA @} EELAIRAGE DE COMPTEURS @) ROcKLICHT (8) LUZ DE COLA 0) CEYPE POUR ALLEMAGNE. ET (9) INSTRUMENTENBELEUCHTUN. (3) ALUMBRADO DE MEDIDORES {Cun sueor) " GEN (10) (MODELOS PARA ALEMANIA Y (1) ALTERNATECR (10) (QEUTSCHER, SCHWEDISCHER SUECIA) (12) REGULATEUR DE CA. Tye. (11) ALTERNADOR ti) FHARE (11), WECHSELSTROMLICHTMA. (12) REGULADOR DE CA (4) FEU ARRIERE SCHINE (13) FARO OS) FEU DEPOSITION (12) wecnseistromaecutaton | (14) LUZ DE COLA (16) ECLAIRAGE DE COMPTEURS (13) SCHEINWERFER (15) LUZ DE POSICION SO RN RURTRERRESSEUR DE. | (ta) ROCKLICHT (06) ALUMBRADOR DE MEDIDORES TENSION, (15). SEITENLICHT (17) REGULADOR/RECTIFICADOR (18) CONTACTEUR D'ALLUMAGE (36) INSTRUMENTENGELEUCHTUN DE TENSION (19) FUSIBLE 10a GEN (18) INTERRUPTOR DE ENCENDIDO @0) BATTERIE (17). SPANNUNGSREGULATOR 109) FUSIBLE 104 GLEICHRICHTER (20) BATERIA (18) ZONDSCHALTER (19) SICHERUNG 104 (20)_ BATTERIE 22-76HONDA XL400R - XLS00R ADDENDUM ‘www hondaxin XL400R-500R SERVICE INFORMATION 2:78 TROUBLE SHOOTING 22-78 BATTERY 22-79 CHARGING SYSTEM 22-80 AC GENERATOR 22-80 VOLTAGE REGULATOR/RECTIFIER 2281 AC REGULATOR 2281 22-77XL400R*XL500R ADDENDUM SERVICE INFORMATION ® SPECIFICATIONS AG generator Charging start Charging output Lighting output Battery capacity Fuse Voltage regulator/rectifier Battery charting rate TROUBLESHOOTING No Power — Key Turned On: 1, Dead battery — Battery not charged — Battery electrolyte evap = Charging system failure 2. Disconnected battery cable 3. Main fuse burned out 4, Faulty ignition switch Low Power — Key Turned On: 1, Weak battery — Low battery electrolyte level — Battery run down — Charging system failure 2, Loose battery connection Low Power — Engine Running: 1, Battery undercharged — Low battery electrolyte level = One or more dead cells 2. Charging system failure 22-78 ‘www.hendaxl it # 1,200 min“ (rpm) 16.8V/2.4A minimum at 2,500 mit * {eLAV/5.5A maximum at 6,000 min’ + 13V minimum at 2,500 min“ (rpm) (rpm) ‘rectifier, 23V maximum at 8,000 min“ (rpm) 2 12V-3AH 104 Transistorized non-adjustable type + 0.38 maximum Intermittent Power: 1, Loose battery connection 2. Leose eharing system connection 3. Loose connection or short circuit in ignition system 4. Loose connection or short circuit in lighting system Charging System Failure: 1. Loose, broken, or shorted wire or connection 2. Faulty voltage regulator/rectifi 3. Faulty AC generator 1. Faulty AC regulator HONDA XL400R-500R tram) 1 At dlaconnect the regulto J eeu in voltage egaaor } At disconnect the AC regulatorHONDA XL400R-XL500R ADDENDUM ‘www hondaxlit XL400R-500R (1) NEGATIVE (-) (2) POSITIVE (+) BATTERY TERMINAL BATTERY TERMINAL © BATTERY Remow: Remove the right side cover. ‘ Disconnect the wires from the battery térmi- als, sNOTE “SSfFRemove the negative cable wire firs, then | remove Disconnect the breather tube from the battery, Remove the bolt and open the battery holder. Remove the battery. (3) BREATHER (4) BATTERY ‘TUBE HOLDER @SPECIFIC GRAVITY TEST Refer to page 16-3 for battery specific gravity test. A SPEGIFIC GRAVITY (20°C/68°F) 1.26—1.28 Full charge 1.220r below —_Underchatge MAXIMUM CHARGING CURRENT: 0.3 amperes. NOTE The XLA00A and XLBOOR hes @ 12V bat tery. Be sure the cherger is set at the 12V range. Installation is the reverse of removal. When installing the battery, be sure to connect (1) CAUTION the breather tube, SIUFON (2) PIPING AS SHOWN BELOW CAUTION (3) BATT’ BREATHER TUBE Be sure the breather tube is roured as (BATT ELBOW shown on the battery caution label. (5) (INSERT THE BATT’ BREATHER TUBE SECURELY) 22-79HONDA XL400R-500R XL400R-XL500R ADDENDUM pruew hondand 1 (1) VOLTAGE REGURATOR/ RECTIFIER COUPLER @ CHARGING SYSTEM . NOTE [Use a Tully charged battery ick the charging system output. Worm up the engine for 10 minutes at 5,000 min” (rpm) before taking reading. Disconnect the black wire from the regulator/rectitier coupler. NOTE _ The terminal is a critical part, Be carofull not to damage Connect a voltmeter and an ammeter to check (2) VOLTAGE REGURATOR/ charging system output. RECTIFIER Start the engine and check the meter readings ‘while increasing engine speed slowly, NOTE [Connect the regulator/rectifier wire as bi fore. ® TECHNICAL DATA Degins at Charging 1,200 min™ (1pm) 2,500 min“ (rpm)_| 16.8V/2.4A min, 8,000 min* (rpm) | 18.4V/5.5A max. Hf there is no charging current, check each charging circuit connection for looseness. If the connections are good, check the alter- nator charging coil for continuity. (3) BATTERY ®AC GENERATOR re (1) AC GENERATOR WIRE COUPLER It is not necessary to remove the stator to make this test, CHARGING COIL: ‘The charging coil is correct if there is con: tinuity between the pink wire and yellow wire, SPECIFIED RESISTANCE: 02-19 LAMP cOiL: ‘The lamp coil is correct if there is continuity between the white/yellow wire and ground. SPECIFIED RESISTANCE: 02-10 If there is: no continuity, it indicates coil open circuit and the stator coil should be replaced with @ new one (page 22-33), 22-80XL400R-XL500R ADDENDUM ‘www.hondax! it XL400R-500R VOLTAGE REGULATOR/ RECTIFIER Check the resistances between the leads with an ‘ohmmeter. NOTE © Use SANWA ELECTRICAL TESTER P/N 07308-0020000 or KOWA ELEC- TRICAL TESTER (TH-5H). ‘© SANWA and KOWA TESTERS have different measurements as shown. © Make sure the tester contains new bat- teries, perform the zero adjustment in the measuring range for accurate read- ‘ings. . (SANWA x ko rerun: (9a 3.) Groen hed Black z= 120 = 3 = = 3=100 (02-20 0.2—10 3-100 @AC REGULATOR ‘AG regurator Remove the headlight and connect voltmeter 3s shown, ‘Select the dimmer switch to ““HI"’ position. Start the engine and check the meter rea hile increasing engine speed slowly. SPECIFIC VOLTAGE: 13.5-14.5V at 5,000 min” (rpm) ings (1) BLUE (2) GREEN 22-81HONDA XL400R-XL500R ADDENDUM ‘www hondaxlit XL400R-S00K (1) AC REGURATOR AC rogulator inspection: Check the resistances between the leads with an ohmmeter, NOTE + Use SANWA ELEGTRIC AL TESTER P/N 07308-0020000 or KOWA ELEC- TRICAL TESTER (THSH). + SANWA and KOWA TESTERS have different measurements as shown. Make sure the tester contains now bat- teries, perform the zero adjustment in ‘the measuring range for accurate read- ings. Tester range: Sa xk i x 1002, Ps eee a. Wit Green = 10-800 22-82HONDA XL400R-500R XL400R-XL500R ADDENDUM ‘www.hondax! it IGNITION SYSTEM (1) COLUNIT (3) SPARK PLUG (2) IGNITION COIL, (4) PULSEGENERATOR (5) PULSE GENERATOR ROTOR (6) ACGENERATOR (7) IGNITION swiTCH (a) ENGINE STOP SWITCH (12) PULSE GENERATOR: (9) SPARK PLUG (10) IGNITION coi (14) AC GENERATOR 22-83HONDA XL400R-500R www.handaxl.it XL400R + SOOR SUPPLEMENT XLAOOR - 500R NACHTRAG XL400R - S0OR APENDICE SERVICE INFORMATION TROUBLESHOOTING IGNITION COIL AC GENERATOR EXCITER COIL CDI UNIT PULSE GENERATOR IGNITION TIMING 22.85 22.85 22.86 22-86 22.87 22-88 22.88 CIRCUIT D'ALLUMAGE, ZONDSYSTEM SISTEMA DE ENCENDIDO INFORMATION WARTUNGSINFORMA- INFORMACION DE D'ENTRETIEN 228s ||| TIONEN 22.85 ||| SERVICIO 22-85 as ||| STORUNGSBESEITIGUNG 22.85 ||| LOCALIZACION DE DEPISTAGE DESPANNES 22.85 Tunes aes || eet ar YALLUMAGE 228 fm BORNE AMSA race BOBINA DE ENCENDIDO 22-86 EXCH WECHSELSTROM. DEUALTERSATEUR, 2286 ||| LicHTMASCHINEN- BOBINA DE EXCITACION ERREGERSPULE 2286 ||| DELALTERNADOR 22.86 UNITE CDI 2287 CDI-EINHEIT 2287 ||| uNIDAD cor 22.87 GENERATEUR D'IMPULSIONS 2288 ||| imPULsLicHTMAscHINe 2288 ||) GENERADOR DE IMPULSIONES 2288 TEMPS D'ALLUMAGE 22.88 ||| ZONDPUNKT 2288 TIEMPO DE ENCENDIDO 22-88 (UNITE Cor (ALLUMAGE PAR 0) COMEINHEIT (1) UNIDAD COI (ENCENDIDO DECHARGE DE CONDENSATEUR) | (2) ZUNDSPULE POR DESCARGA DE CON: (2) BODINE D'ALLUMAGE (3) ZONDKERZE DENSADOR) (3) BOUGIE D’ALLUMAGE {@) INPULSLICHTMASCHINE (2) BOBINA DE ENCENDIDO (8) GENERATEUR D'IMPULSIONS (5) IMPULSLICHTMA (3) BUIIA DE ENCENDIDO. 6 ©) @ ® @ «19) an, 2) a3) «ay ROTOR DU GENERATEUR DIINPULSIONS ALTERNATEUR ‘CONTACTEUR D‘ALLUMAGE ‘CONTACTEUR D'ARRET DU MOTEUR ‘ROUGIE D’ALLUMAGE BOBINE D'ALLUMAGE UNITE CDI GENERATEUR D'"IMPULSIONS BOBINE D'EXCITATION ALTERNATEUR 6 am 8) 9) (io) (a) (2) (3) (ay SCHINENROTOR WECHSELSTROMLICHTMA, SCHINE ZONOSCHALTER MOTORABSTELL. SCHALTER ZONOKERZE ZONDSPULE COLEINHEIT IMPULSLICHTMASCHINE EAREGERSPULE WECHSELSTROM. LICHTMASCHINE GENERADOR OE IMPUL: SIONES ROTOR DEL GENERADOR DE_IMPULSIONES ALTERNADOR INTERRUPTOR DE ENCEN: DIDO INTERRUPTOR DE PARADA DE MOTOR BUJIA DE ENCENDIDO BOBINA DE ENCENDIDO UNIDAD COI GENERADOR DE IMPUL- SIONES BORINA DE EXCITACION ALTERNADOR 22-84 ©HONDA XL400R-500R XL400R-XL500R ADDENDUM www.handaxl.it SERVICE INFORMATION GENERAL INSTRUCTIONS The XLAOOR and XLSOOR uses an electrical ignition timing advance system, If the. ignition timing advance is incorrect, ‘check the CDI unit and replace it if necessary. ® SPECIFICATIONS ‘Spark plugs: | LA00R, XL500R ‘XLBOOR_U, D type 3 DRBES.L (NGK} or DBEA INGE) or Seat X24ESR-U (ND) X24E8-U (ND) For eold dimate DAVES (NGK) or O7EA (NGK) or (Below 5°C/a1°F): X22€SR-U (ND) ____x2288-U (ND) : ‘ding. | ORBES (NGK) oF DEA (NGK) or For extended high speed riding X27ESR-U (ND) X276S-U (ND) Spark plug gap: 0.60.7 mm (0.024-0.028 in) Ignition timing (Initial): 10°BTDE at 1,200 min“ (rpm) (Full advance): 38°BTDC at 3,500 min“! (rpm) (XLSOOR) 35° BTOC at 3,000 min“ (rpm) (XL400R) TROUBLE SHOOTING No Spark at Plug Engine Starts But Runs Poorly 1. Engine stop switch “OFF 1. Ignition primary eireuit 2. Poorly connected, broken or shorted wires — Faulty ~ Between CO! unit and engine stop switch — Loose or bare wire - = Faulty pulse generator = Between CDI unit and ignition switch 2. Secondary circuit — Between ignition coil and spark plug — AC generator faulty — Between pulse generator and CDI unit = CDI unit faulty . Faulty ignition switch — Faulty pulse generator }. Faulty ignition coil Faulty CDI unit AC generator faulty . Faulty pulse generator somee 22-85HONDA XL400R-500R XL400R-XL500R ADDENDUM www.handax! it (1) IGNITION COIL @IGNITION COIL, move: Remove the fuel tank, Disconnect the wire leads, Remove the attaching screws and remove the coll. Inspection: Measure the resistances of the primary and secondary coils. PRIMARY: — 0.2-0.390 SECONDARY: 3.4-4.2k0 (1) AC GENERATOR COUPLER @AC GENERATOR EXCITER COIL Disconnect the AC generator wire coupler. Measure the resistance between the black/read wire and ground, SPECIFIED RESISTANCE: 50-2002 (2) GROUND 22-86XL400R-XL500R ADDENDUM ‘www.handaxl it HONDA XL400R-500R (1) DUST COVER CD! UNIT Remove the dust cover and disconnect the couplers. Remove the CDI unit, Cheek continuity between the CDI terminals. Replace the CDI unit if the readings do not fall Within the limits shown in the table, NOTE + The CDI unit is fully transistorized. * For accurate testing, it is necessary to Use a specified electric tester. Use of an improper tester or measurements in improper range may give a false read- ings. * Use SANWA ELECTRICAL TESTER (P/N 07308-0020000) or KOWA ELEC. | TRIGAL TESTER (THSH), SANWA xk KOWA x 1002, (2) COL UNIT =O feet sw ext a0 | =] 30-300 T0=200 (0-100) (5~50) 01-20 Needle swings and returns to 2, [1 = Specification fer the XL400R, 22-87XL400R+XL500R ADDENDUM ‘www.handaxl it HONDA XL400R-500R @PULSE GENERATOR Disconnect the pulse generator wire coupler and measure the resistance between Blue/ Yellow and Green/White terminals, SPECIFIED RESISTANCE: 510-5708 (1) INDEX_MARK IGNITION TIMING Remove the timing hole cap. ‘Connect a timing right and tachometer. Start the engine and check the ignition timing: (2) F MARK IGNITION TIMING SPECIFICATIONS (1) PULSE GENERATOR WIRE COUPLER (3) FULL ADVANCE MARKS 3,400 — 4,000 min (rpm) 1,200 — 2,000 min’ |__ 2,900 — 4,000 min“ (rpm) The index mark should be aligned with F mark. Timing advance should start, “Timing advance should craze. ‘The index mark should be between | ‘the full advance mark. 22-88HONDA XL400R » XL500R ADDENDUM wan hondaxlit XL400R-5O0R SWITCHES SERVICE INFORMATION 22.90 TROUBLESHOOTING 22-90 IGNITION SWITCH 22-91 LEFT HANDLEBAR SWITCH 22-92 FRONT STOPLIGHT SWITCH 22-93 ENGINE STOP SWITCH 2293 22-89HONDA XL400R°XL500R ADDENDUM ‘www hondaxd.it XL400R-500R SERVICE INFORMATION © GENERAL INSTRUCTIONS * Some wires have different colored bands around them near the connector. These are connected to other ‘respond with the band color. + All plastic plugs have focking tabs that must be released before disconnecting, and must be aligned when reconnecting, + To isolate an electrical failure, check the cantinuity of the electrical path through the part. A continuity check can usually ‘be made without removing the part fram the motoreycle — by simply disconnecting the wires and connecting a continuity tester or voltmeter to the terminals or connections. ires which cor- © SPECIFICATION XLB00R XLA00R Headlight (high/low) 12V-35/35W 12V-26/96W 12V-36/36W (F type) Tail/stoptight 12V-S/21W 12V-8/21W. Turn signal light 12V-21W 12V-21W 12V—23W (D, U, SA type) ‘Speedometer light 42V-1.7 ‘Tachometer light 12V-3.4W Neutrat indicator light 12V-3.4W ‘Turn signal indieator light 12v-3.4W High beam indicator light q2V=1.70 Position tight 12v-4w TROUBLESHOOTING ‘No Lights Come On Whan Ignition Switch Is Tuened ON: 41. Bulb at fault or burned out 2. Faulty switch 3. Wiring to that component has open circuit 4. Fuse blown 5. Wiring loose, broken, of'st fault 6. Battery dead or disconnected Alll Lights Come On, But Dimly, When Ignition Switeh Is Turned ON: 1. Battery voltage low 2. Wiring oF switch hes excessive resistence Headlight Beam Does Not Shift When HI-LO Switeh Is Oparated: 1. Bearn filament burned out 2, Faulty dimmer switch