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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Models Covered & Key Technical Specifications
Honda Fourtrax Foreman 400, TRX400FW — 1995–2003 Precision Engineering Repository | Foreman 400 Series Folder
- Factory End Play Data is set to 0.80 mm (0.031 in) Specifications
- Measured Power Framework corresponds to 20.9 kW (28 hp) Requirements
- Calibrated Compression Ratio requires 8.2:1 Logic
- Engineered Torque Data dictates 39.9 cc (24.10 cu in) Threshold
- Certified Bore Diameter reaches 66 × 68 mm (3.39 × 2.68 in) Mapping
- Integral Fuel Capacity is standardized to 12.0 liter (3.16 US gal, 2.64 Imp gal) Configuration
Professional Workshop Service Manual & Technical Specifications
Practical Electrical Manual: Precision Repair Handbook: Honda Fourtrax Foreman 400, TRX400FW (1995-2003) Workshop-Compendium
Engine-Type: Honda Fourtrax Foreman 400, TRX400FW (1995-2003) // Equipment-Series: Four-Wheel Drive, Dual-Purpose Utility Logic // Technical-Scope: Service specifications, system documentation, repair architecture.
| Documentation Category | System Coverage | Reference Materials |
|---|---|---|
| Powertrain Integration | Crankshaft, transmission, differential architecture | Complete specifications included |
| Electrical Configuration | Alternator, battery, charging regulation | Documented across multiple sections |
| Operational Procedures | Maintenance sequences, component servicing | See Chapter index |
Repair data is categorized into frame assembly specifications, engine removal and installation, and drivetrain component procedures covering longitudinal crankshaft operation and limited slip differential integration. The manual presents information on cylinder head servicing, valve train adjustment, and lubrication system architecture. Service intervals are documented for suspension components, brake system maintenance, and gear case operation. Component locations are identified for front and rear driving mechanisms, steering shaft assemblies, and auxiliary systems. Reassembly procedures are specified for crankshaft and balancer installation, transmission gear engagement, and differential bearing replacement.
Strategic Nexus
The document addresses integrated electrical systems including the battery charging architecture, regulator/rectifier operation, and DC-CDI ignition control module interaction. Logically requiring attention to fuel system delivery, carburetor adjustment protocols, and air cleaner element maintenance standards. The manual documents torque specifications for fastener assemblies throughout the frame, engine, and drivetrain to ensure proper component retention. Technical procedures encompass clutch system operation, change clutch disassembly sequences, and centrifugal clutch mechanism inspection criteria.
Technical Logic-Path
Drivetrain specifications are addressed in chapters detailing primary drive gear geometry, constant mesh transmission configuration, and final reduction ratio documentation. The manual includes wiring diagrams showing battery interconnection, starter motor relay circuits, and indicator lamp configuration for neutral and reverse engagement verification. Service information describes the OHV valve train architecture with push rod actuation, camshaft-driven rocker arm systems, and valve timing mark alignment procedures. Reference data for front differential backlash inspection, ring gear tooth contact pattern verification, and pinion bearing preload adjustment is documented.
Modular Threshold
Suspension system documentation encompasses front shock absorber disassembly procedures, spring seat replacement sequences, and damper rod lock nut torque specifications. The document provides detailed illustrations of swingarm pivot bearing replacement, dust seal installation methods, and breather tube routing configurations. Electrical system sections include alternator cover disassembly, stator winding resistance measurement data, and ignition pulse generator inspection protocols. Brake system chapters cover wheel cylinder bore specifications, brake shoe lining thickness service limits, and hydraulic fluid bleeding procedures for front brake drum and rear brake panel assemblies.
Integrated Standard
Troubleshooting logic identifies performance conditions mapped to component inspection sequences, system testing procedures, and probable cause documentation without prescriptive repair instructions. The manual documents torque specifications for the differential case mounting bolts, pinion joint fasteners, and drive shaft connection hardware to ensure structural integrity. Technical data includes compression ratio specifications, valve timing angle measurements, and fuel tank capacity documentation. Component inspection sections describe bearing turn-smoothness evaluation criteria, dust seal lip condition assessment standards, and gasket surface integrity verification parameters without delivering repair direction.
Strategic Methodology
The document references specialized tools designed for crankshaft removal, differential inspection, and clutch component extraction, cataloging tool numbers and attachment specifications for proper assembly positioning. Lubrication system documentation identifies oil capacity requirements at draining, disassembly, and filter change intervals, plus oil passage locations within crankcase and cylinder head architecture. The manual provides wiring diagram reference indexes, switch terminal continuity specifications, and connector pin assignments for headlight circuit operation, starter relay function verification, and neutral indicator lamp engagement testing.
Note: This manual provides comprehensive technical reference material for the 1995-2003 Honda Fourtrax Foreman 400/TRX400FW four-wheel drive utility vehicle, documenting factory specifications across powertrain, chassis, electrical, fuel, and brake systems. Original published material language is Italian; English translations of primary service data are included.
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