2004 Honda TRX400FA FourTrax AT ATV Owner's Manual (P/N 00X32-HN7-6000)

Honda’s 2004 TRX400FA FourTrax AT owner’s manual explains the controls, riding practices, and owner maintenance for this recreational 400cc-class ATV. The back cover carries document codes 32HN7600 / 00X32-HN7-6000; copyright Honda Motor Co., Ltd., 2003.

Printable PDF, Contents, and Index

Text search and topic navigation: PDF text search and embedded bookmarks are not available. The printed contents pages, section topic lists, and index provide references for locating information.

One printable English PDF contains 235 pages: 225 numbered manual pages, nine opening pages covering the front cover, copyright, title, introduction, safety notes, and contents overview, plus one back cover. These opening and cover pages are already included in the total.

FourTrax Controls, Owner Service, and Troubleshooting

The selected topics below highlight the operating and maintenance coverage. Additional material includes accessory-socket use and guidance on gasoline containing alcohol.

• Drive modes and starting: AUTO and ESP operation, selectable 2WD/4WD, electric and recoil starting, reverse operation, and transmission warning indications.

• Oil and filtration: Step-by-step procedures for engine oil and filter replacement, front differential and rear gear case oil changes, and air-cleaner servicing.

• Engine adjustments: Throttle freeplay adjustment, choke cable checks, idle-speed and air-fuel mixture adjustment, spark plug inspection, and spark arrester cleaning.

• Drum brakes and chassis: Front brake lining-clearance adjustment, rear lever and pedal freeplay adjustment, shoe wear inspection, water drainage, and driveshaft boot checks.

• Battery and fuses: Battery removal, charging and storage guidance, fuse replacement, and illustrations identifying the main, control-motor, and circuit fuses.

• Unexpected problems: Starting and poor-running symptom tables, transmission malfunction guidance, oil-temperature warnings, temporary tire repairs, and emergency wheel removal.

Owners with basic mechanical skills can use the documented routine-maintenance procedures; Honda assigns more demanding work requiring special tools to qualified mechanics.

Operational Overview and Controls

The instrument pages explain the multi-function display, gear position indicator, oil-change reminder, and handlebar shift switches. Component-location illustrations identify the fuel valve, choke knob, ignition switch, and starting primer.

AUTO and ESP are selectable modes on the same ATV. Shifting-sequence illustrations accompany the instructions, and the drive-selection section explains engagement and indicator behavior, including the return to 2WD when the engine is restarted. These explanations provide a reference for checking reported operating problems before planning a repair.

Moving the gearshift lever while the ATV is moving can damage the sub-transmission; the shifting section identifies this operating precaution.

Pre-ride checks address oil level, tires, brakes, and controls. Loading guidance covers cargo racks, towing, tongue weight, and accessories, while the riding sections address hills, slopes, obstacles, water crossings, and parking. Follow the documented load limits and maintenance schedule before operating the ATV.

Engine, Carburetor, and Lubrication Service

Oil-service coverage includes an oil-filter assembly illustration, dipstick inspection drawings, lubricant recommendations, refill quantities, and fastener torque specifications. Incorrect oil-filter installation can cause serious engine damage.

Air-cleaner instructions cover foam-element cleaning and oiling, housing-cover orientation, and drain-tube cleaning. The oil-filter procedure requires mechanical skill and tools beyond the supplied tool kit.

Throttle-stop and pilot-screw adjustments are described. The high-altitude carburetor table shows jetting and adjustment differences, but jet-installation procedures belong to the separate Honda Shop Manual.

The valve section provides a clearance specification and explains the effects of incorrect clearance. Valve-adjustment instructions are assigned to that separate manual.

Brake Inspection and Tire Service

The front brakes are hydraulic drums, and the rear drum brake is mechanically operated. Illustrations show front shoe-lining inspection, brake adjusters, and the external rear brake wear indicator. Brake bleeding and shoe replacement are referred to a Honda dealer.

Tire guidance distinguishes temporary trail repairs from permanent professional repairs. Emergency wheel removal and installation include wheel-nut orientation and tightening specifications.

Starting Checks and Repair Limits

Troubleshooting tables distinguish a starter that does not operate from an engine that cranks without starting, then address poor running. The Circuit Fuse Access illustrations identify circuit fuses and spares, alongside separate main-fuse views.

Transport and storage instructions cover tie-down locations, carburetor draining, battery care, and return-to-service checks.

This owner’s manual provides maintenance procedures and basic fault checks. Internal engine and transmission repair require separate workshop documentation; electrical wiring diagrams are not included.

Selected Throttle and Idle Adjustment Data

Throttle-lever freeplay is specified as 3–8 mm (0.1–0.3 in), alongside cable inspection and adjustment instructions.

For idle-speed adjustment, the engine must be at normal operating temperature. The specified setting is 1,400 ± 100 rpm in neutral, and the procedure calls for a tachometer.