1999-2002 Honda TRX400EX Service Manual
Honda TRX400EX Service Manual covers procedures for engine removal, fuel system, and suspension. PN 07965-VM00100.
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Models Covered & Key Technical Specifications
Honda TRX400EX — 1999–2002 (07965-VM00100) Operational Primer Vault | TRX400EX Series Dossier.
- Approved End Play: 397 cm³ (24.2 cu-in) is measured at the single-cylinder displacement Architecture.
- Baseline Power Framework: For optimal performance, 147 W at 5,000 rpm maintains the alternator charging capacity Topology.
- Verified Ambient Limits: The compression ratio produces 9.1:1 and represents the cylinder head pressure Matrix.
- Designated Torque Data: Fuel tank volume requires 10 liters (2.6 US gal, 2.2 Imp gal) for the complete fuel system Standards.
- Certified Measurement Bounds: The engine oil capacity delivers 1.85 liters (1.95 US qt, 1.63 Imp qt) at filter change Margin.
- Reference Dimensional Limits: Battery specification limits 12V - 8Ah (nominal 96 Wh) as the electrical energy storage Protocol.
Manual Description & Preview
Applied Calibration Field Manual: Honda TRX400EX Service Manual Maintenance-Registry
| Procedure-Type: Service Manual // Component-Focus: Engine, Fuel System, Suspension, Electrical Systems, Transmission, Brakes, Wheels, Steering // Procedure-Type: Workshop Manual | Specification | Baseline | Context |
|---|---|---|---|
| Tire Tread Depth | 4.0 mm (0.16 in) | Standard Minimum Tread | |
| Cold Tire Pressure | 27 kPa (4.0 psi) | Standard Tire Pressure | |
| Idle Speed | 1,400 ± 100 rpm | Engine Idle Speed | |
| Valve Clearance (Intake) | 0.10 mm (0.004 in) | Valve Clearance Specification | |
| Valve Clearance (Exhaust) | 0.12 mm (0.005 in) | Valve Clearance Specification | |
| Engine Oil Capacity (After Draining) | 1.8 liters | Engine Oil Capacity |
Technical chapters are organized around systems, procedures, and introductions. Sections cover detailed component information, maintenance schedules, and troubleshooting guides. The document includes a comprehensive overview table of specifications and performance parameters. Key system information is presented, followed by specific procedures for maintenance and repair, an introductory overview, a detailed specifications table, and essential troubleshooting steps to ensure proper vehicle operation and longevity.
Installation guidelines are provided for all major component assemblies including the engine, suspension, and fuel system, ensuring correct fitment and function.
Maintenance guidelines are included for routine servicing, covering areas such as fluid changes, filter replacements, and lubrication to maximize performance and lifespan.
OEM guidelines are included for factory-standard procedures, ensuring that all repairs and adjustments meet manufacturer specifications for optimal safety and reliability.
Transmission service information covers disassembly, inspection, and assembly of internal components for smooth gear shifting and durability.
HVAC system procedures are included for the cooling system and related components, ensuring efficient thermal management.
This manual documents torque specifications for critical fasteners to ensure proper assembly and prevent corrosion joint prevention.
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