How to Change the Oil in a 2004 Honda XR400R

Shop parts for a 2004 Honda XR400R Dirt Bike.

Changing the oil in your 2004 Honda XR400R is a critical maintenance task that ensures optimal engine performance and longevity. The XR400R features a dry-sump engine, which means the oil is stored in a separate tank rather than in the crankcase. This setup requires a slightly different approach compared to some other dirt bikes. Below you'll find a step-by-step guide to changing your bike's oil, including the specific tools you'll need and key model-specific notes.

Tools and Supplies Needed

  • Socket wrench set
  • Screwdrivers
  • Oil drain pan
  • Funnel (preferably with a long neck)
  • Clean rags or shop towels
  • New oil filter (with rubber sealing)
  • Replacement O-ring for the filter cover (recommended)
  • Engine oil (Approx. 1.7-2.0 liters of 10W-40, Honda GN4 recommended but not required)
  • Rubber gloves (optional, but keeps your hands clean)
  • Measuring container for oil

Step-by-Step Oil Change Procedure

  1. Warm Up the Engine
    • Start the motorcycle and let it idle for several minutes. This warms the oil so it drains more easily and thoroughly.
  2. Position the Bike Safely
    • Place the XR400R on a stable, level surface or center stand.
  3. Remove the Drain Plugs
    • There are two oil drain plugs on the XR400R: one on the engine crankcase and another on the oil tank (typically located on the frame, front down tube).
    • Put the oil pan under the first drain plug and use your socket wrench to carefully remove it. Allow the oil to drain completely.
    • Move the pan and remove the second drain plug, letting the remainder of the oil drain out.
  4. Replace the Drain Plugs
    • After oil has drained, inspect the drain plug washers for wear and replace them if needed.
    • Reinstall both plugs carefully and tighten them to the manufacturer's torque specifications.
  5. Change the Oil Filter
    • The oil filter is located behind a small cover secured by two bolts.
    • Remove the cover with your socket or screwdriver, being careful as a spring may push the cover outward.
    • Remove the old oil filter, noting its orientation. Compare the new filter against the old for a match. Ensure the rubber sealing on the new filter faces outward when installing.
    • Lubricate the new O-ring for the cover with a bit of used oil and put it in place. Carefully reinstall the oil filter cover, pressing it in while tightening the bolts evenly and gently.
  6. Refill with Fresh Oil
    • Remove the oil fill cap (dipstick) on the oil tank. Use a longneck funnel to avoid spills.
    • Pour in about 1.7 to 2.0 liters of 10W-40 engine oil. Pour slowly, stopping periodically to check the level with the dipstick.
    • XR400R Model-Specific Call-Out:
      • Be careful not to overfill. Overfilling can cause oil foaming and engine issues. The oil level should be at the upper mark on the dipstick when checked without screwing it in, and with the bike upright after the engine has circulated the oil.
  7. Prime and Check the Oil Level
    • After refilling, kick-start the engine by hand a few times (with the ignition off) to help circulate the oil through the system before running the engine

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    • Start the engine and let it idle for a few minutes. Turn it off and allow the oil to settle for a minute or two.
    • Re-check the oil level with the dipstick (again, don't screw it in to check). Top up as needed, but do not exceed the upper mark

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  8. Dispose of Old Oil and Filter Properly
    • Take the used oil and filter to a local recycling center or designated disposal facility.
  9. Clean Up
    • Wipe off any spilled oil from the bike and your tools. Double-check for leaks around the drain plugs and filter cover.

XR400R-Specific Notes and Pro Tips

  • The 2004 XR400R uses a dry-sump lubrication system, requiring both the engine and frame tanks to be drained and refilled.
  • Double-check the oil filter orientation: incorrect installation can cause engine damage. The rubber seal must always face outward

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  • Always allow oil to settle and circulate through a brief idle and shut-off before the final oil level check.
  • Use the correct oil viscosity (10W-40) for optimal clutch and engine life. While Honda GN4 is recommended, any good motorcycle-specific oil of this grade is generally acceptable

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  • Check oil levels regularly in the rides following your oil change to confirm no leaks or drops in level

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Changing your oil regularly–every 1,000km or after heavy riding–helps keep your XR400R running like new. For all your oil, filters, and maintenance needs, visit MotoSport.com.

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Disclaimer: This guide is provided for general informational purposes only and is not intended to replace your motorcycle's official owner's manual. Always refer to your manufacturer's documentation for model-specific instructions, torque specifications, safety procedures, and maintenance requirements. If you are unsure or inexperienced, consider seeking assistance from a qualified mechanic or technician.