1995-2003 Honda Fourtrax Foreman 400 TRX400FW Service Manual

Covers complete service procedures for Honda Fourtrax Foreman 400 with engine rebuild, transmission overhaul, electrical diagnostics. Complete specifications and torque values provided throughout.

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Technical Safety Notice
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This official OEM document is intended for professional technicians and skilled operators. Performing service on mechanical equipment involves inherent risks. By purchasing, you acknowledge that RepairLoader provides original manufacturer data for informational purposes. Always prioritize safety: use correct tools, wear protective gear, and consult a certified professional if you are uncertain of any procedure.

Honda Models Covered & Key Technical Specifications

Models: Honda Fourtrax Foreman 400, TRX400FW
Build Years: 1995–2003
Technical Data:

  • Engine displacement: 394.9 cc (24.10 cu-in)
  • Bore and stroke: 86 × 68 mm (3.39 × 2.68 in)
  • Compression ratio: 8.2:1
  • Cooling system: Air cooled
  • Fuel capacity: 12.0 liters (3.16 US gal)
  • Transmission: 5-speed with reverse
Technical Specifications
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Document Number / Seller:
24805 / Karen Peterson
File Size:
30.66 MB
File Type:
PDF
Language:
English
Pages:
370
Printable:
Yes
Category:
ATV
Last updated / verified
Mar 15, 2026

Honda Manual Features & Content Preview

Official 1995–2003 Honda Fourtrax Foreman 400 Service Manual

  • Covers 1995–2003 Honda Fourtrax Foreman 400 and TRX400FW ATV models
  • Genuine OEM publication with detailed internal specs for the 394.9 cc air-cooled engine
  • Contains hundreds of pages of exploded-view diagrams, electrical schematics, and torque specifications
  • Delivered as a direct download the moment payment clears
  • Indexed PDF search covers every chapter and appendix
  • Stored against your account so you can retrieve it after a hard-drive loss
  • This 370-page official Honda publication remains the authoritative reference for the 1995–2003 TRX400FW series

Contents Coverage

The 1995–2003 Honda Fourtrax Foreman 400 service manual provides full documentation across twenty-four distinct chapters. Primary sections encompass the engine, chassis, and electrical architecture, starting with general safety and model identification. The document details the engine removal and installation, cylinder head and piston assembly, transmission, and clutch mechanisms. Chassis sections outline the suspension, steering, front and rear driving mechanisms, and brake systems, while the electrical section provides wiring diagrams and starter system specifications.

Technical Data Preview

The manual includes extensive tables for torque values, fluid capacities, and mechanical clearances. Cylinder compression is specified at 1,226–1,442 kPa (12.5–14.5 kg/cm²) when the decompressor is not activated. Engine oil capacity is documented at 2.0 liters for standard draining and 2.1 liters following an oil filter change. The front and rear drive final reduction gear systems are specified to use Hypoid gear oil SAE #80. Valve clearance for both intake and exhaust is listed at 0.15 mm (0.006 in) in the cylinder head maintenance tables.

Reference only — always consult a certified technician before performing service on this equipment.

An official 370-page Honda OEM service manual covering the 1995–2003 Fourtrax Foreman 400, documenting engine, chassis, electrical, and fuel-system specifications for the TRX400FW build.

Document Reference: Honda Publication P/N not specified on cover; OEM factory manual identity confirmed.

Manual FAQ, Purchase & Download Details

Is there a reference to component breakdown diagrams or exploded views for the major assemblies in the manual? keyboard_arrow_down

Manual includes system illustrations for various assemblies throughout the chapters to show how components are grouped.

Can I preview the chapter coverage to see what systems are addressed for the Fourtrax Foreman 400? keyboard_arrow_down

Table of contents lists sections covering the engine, drive train, chassis, and electrical systems. This preview helps confirm that major areas like the lubrication system, fuel system, and ignition system are detailed in the document.

Does the manual include specific sections for charging, ignition, and lights or switchgear? keyboard_arrow_down

Yes, sections 17 through 20 are dedicated to the battery and charging system, ignition system, electric starter, and lights and switches.

Are there lookup tables that reference standard torque values and tool requirements? keyboard_arrow_down

Manual features comprehensive torque value tables in the general information section categorized by fastener type. It also provides a dedicated tools table that lists necessary reference numbers for various components.

Which specification tables contain technical data like clearances and tolerances? keyboard_arrow_down

General information section contains extensive specification tables covering engine bore and stroke, cylinder compression, and valve clearance references. These tables also list service limits for critical components like the transmission gears, crankshaft, and piston ring end gaps. You can refer to these pages for standardized configuration data and mapping.

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