1999-2004 Honda TRX400EX Fourtrax Service Manual
Shop manual for TRX400EX with complete engine assembly procedures and transmission service. Includes carburetor QB10A specs and torque value charts.
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Sample pages from the 1999-2004 Honda TRX400EX Fourtrax Service Manual manual
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Models Covered & Key Technical Specifications
Honda TRX400EX Fourtrax — 1999–2004 Specialized Reference Library for TRX400EX Suite.
- Authorized Thermal Envelope: Single cylinder configuration reaches 397 cm³ (24.2 cu-in) displacement volume Requirements.
- Published RPM Specs: Engine performance achieves maximum output at 5000 rpm horsepower rating governs operational efficiency Threshold.
- Reference Physical Specs: Bore and stroke dimensions measure 85.0 × 70.0 mm (3.35 × 2.76 in) is specified as piston architecture Mapping.
- Established Coupling Torques: Primary engine compression supports 9.1:1 ratio for combustion chamber pressure Configuration.
- Measured System Fill: Fuel tank capacity provides 10 liters (2.6 US gal, 2.2 Imp gal) reservoir volume Benchmarks.
- Core Cooling Specs: Engine oil capacity reaches 1.8 liters (1.9 US qt, 1.6 Imp qt) after draining for maintenance Range.
Professional Workshop Service Manual & Technical Specifications
Advanced Instructional Repair Manual: ATV Field-Ready: Honda TRX400EX Fourtrax (1999-2004) Calibration-Manual
Technical-Benchmarks: TRX400EX Fourtrax (1999-2004) // Year-Coverage: 1999-2004 Model Years / Multi-System Engine Documentation // Model-Designation: Single-Cylinder Four-Stroke ATV Service Reference.
| Service-Nexus | Baseline | Calibration-Standards |
|---|---|---|
| Engine Systems | 400cc Single-Cylinder | Complete specifications provided |
| Drivetrain Assembly | 5-Speed Transmission | See Chapter 9, 11 |
| Suspension Network | Double Wishbone Front / Swingarm Rear | Documented throughout sections 12-13 |
| Brake Architecture | Hydraulic Disc Dual Circuit | Reference data in Chapter 14 |
| Electrical Framework | CDI Ignition / Electric Start | Sections 15-18 included |
Documentation sections include the engine and transmission systems, proceeds to fuel and cooling network, and encompasses frame and body panel assemblies. The manual documents carburetor calibration alongside ignition pulse generation, explores suspension arm pivot bearing specifications, and concludes with comprehensive electrical circuit documentation.
Systematic Standard
Component locations are identified for the fuel delivery architecture, including tank breather routing and carbureted air intake passages. The document provides detailed assembly drawings showing primary drive gear engagement, clutch lifter mechanism positioning, and crankcase bearing placement. Fastener routing diagrams display throttle cable paths, brake hose clamp locations, and handlebar switch wire harness configuration across the frame structure.
Modular Nexus
Service procedures are documented for complete clutch disassembly and reassembly operations, featuring exploded component views of pressure plate and friction disc stacks. The manual includes systematic guidance for rocker arm and sub-rocker arm shaft removal, camshaft bearing inspection methodology, and valve stem seal installation protocols. Transmission gear bushing clearance measurement procedures are provided alongside shift fork repositioning techniques within the shift drum guide groove network.
Advanced Standard
Calibration requirements are specified for spark plug gap adjustment, idle speed establishment via throttle stop screw positioning, and fuel mixture control through pilot screw opening documentation. The reference material includes valve clearance specifications for both intake and exhaust systems, along with cylinder head bolt tightening sequences in crisscross patterns. Suspension preload adjustment reference data and brake fluid specification documentation support proper component maintenance intervals.
Strategic Logic-Path
Electrical system documentation covers charging coil resistance measurement, alternator output capacity specifications, and battery voltage parameters throughout operating cycles. The manual documents battery terminal connection sequencing, starter motor brush length service limits, and neutral switch continuity verification procedures. Ignition system sections reference ignition timing mark alignment with crankshaft position indicators, spark plug electrode gap measurement methodology, and ignition pulse generator voltage output standards.
Precise Protocol
Suspension service documentation covers shock absorber spring installed length specifications, swingarm pivot bearing needle roller quantity and seating depth, and steering shaft holder bushing inspection procedures. The manual documents torque specifications for engine fasteners including cylinder head nuts, rocker arm shaft locking agent application, and crankshaft bearing setting plate bolt tension. The document provides comprehensive rear axle lock nut assembly procedures featuring stopper ring installation sequence and brake disc hub assembly guidance.
The service manual documents torque specifications for the cylinder bolts to ensure proper gasket sealing and consistent clamping load distribution throughout the engine block assembly network.
Installation guides encompass complete engine removal and installation procedures detailing hanger nut positioning, support block placement methodology, and wire harness routing verification before final assembly. Maintenance schedule tables reference service intervals in hours and kilometers, identifying components requiring cleaning, adjustment, lubrication, or replacement at specific operational milestones. Troubleshooting flow charts provide diagnostic decision trees for engine starting issues, performance complaints, and electrical system malfunction investigation pathways.
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