2005-2012 Honda TRX400EX/X ATV Service Manual
Service procedures, parts diagrams, and torque specifications for the Honda TRX400EX and TRX400X ATVs. Complete repair data for engine, transmission, suspension, brakes, and electrical systems.
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Models Covered & Key Technical Specifications
Honda TRX400EX, TRX400X — 2005–2012 Authorized Precision Archive | TRX400 Series Segment.
- Authorized Volume Data: 397 cm³ (24.2 cu-in) is configured at the single-cylinder transverse displacement Mapping.
- Critical Charge Quantity: Bore and stroke measures 85.0 × 70.0 mm (3.35 × 2.76 in) produces engine architecture Configuration.
- Operational End Play: The compression ratio maintains 9.1:1 for optimal combustion chamber pressure Benchmarks.
- Fundamental Cooling Specs: Air cooled with oiled urethane foam filtration is established at 42.5 kg (93.7 lbs) dry weight Range.
- Specific Mass Specs: Maximum fuel tank capacity reaches 10 liters (2.6 US gal, 2.2 Imp gal) operational reserve Sequences.
- Maximum Twist Specifications: Primary engine torque requires 108 N·m (11.0 kgf·m, 80 Ibf·ft) on the clutch center lock nut Baseline.
Professional Workshop Service Manual & Technical Specifications
OEM-Grade Technical Manual: Official Honda TRX400EX/X ATV Repair & Maintenance Manual - 2005-2012 Coverage Library-Master
Serial-Range: Honda TRX400EX, Honda TRX400X // Procedure-Type: Service Documentation / Complete Systems Logic // Operational-Scope: Comprehensive Powertrain and Chassis Documentation.
| Integrated-Framework | System-Path | Context |
|---|---|---|
| Engine Assembly & Cylinder Head | Four-Stroke Single-Cylinder Operations | Complete valve clearance procedures and specifications documented |
| Transmission & Crankcase | Power Delivery Through 5-Speed Gearbox | Full disassembly sequences with torque requirements included |
| Hydraulic Brake Systems | Front & Rear Braking Components | Caliper assembly procedures and fluid specifications provided |
| Electrical Architecture | Battery, Charging & Ignition | Peak voltage testing protocols and component inspection methods documented |
| Frame & Suspension | Chassis Geometry & Damping | Bearing replacement procedures and wheel alignment data included |
Operational Logic-Path
Technical content addresses the complete 2005-2012 model year specifications, requiring comprehensive knowledge of OEM factory procedures. The manual documents valve adjustment specifications, spark plug gaps, and tire pressure standards while providing system-wide assembly sequences. Strategically requiring technician competency across engine disassembly, this resource consolidates procedures for cylinder head removal through crankshaft bearing replacement, transmission gear inspection, and final drive chain adjustment protocols.
Structured Protocol
Service procedures are documented for the engine lubrication system with emphasis on oil capacity requirements and pump rotor clearances. Calibration requirements are specified for carburetor float levels, pilot screw positioning, and idle speed adjustment at 1,400 ± 100 rpm minimum. The document encompasses detailed specifications for both primary and secondary ignition systems, including peak voltage thresholds and alternator exciter coil resistance measurements at factory temperature conditions.
Modular Standard
Electrical system documentation covers battery maintenance protocols, charging voltage inspection methods, and regulator/rectifier testing procedures. Suspension service documentation covers front wishbone arm pivot bearing replacement, shock absorber needle bearing installation, and rear swingarm pivot maintenance sequences. The manual documents torque specifications for critical fastening points throughout the frame structure, ensuring proper clamp load consistency across engine-to-chassis mounting locations.
Advanced Benchmarks
Disassembly instructions are documented for both front and rear brake caliper systems, including piston seal replacement and pad pin installation sequences. The resource provides wiring diagram schematics for all electrical circuits—including starter relay operation, neutral/reverse switch logic, and ignition control module functionality. Comprehensive sections address fuel system cleaning procedures, main jet sizing variations by altitude, and carburetor air/fuel mixture adjustment protocols. The manual documents specifications for transmission gear bushings, shift drum guide groove tolerances, and countershaft bearing end-play measurement standards.
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