TRX 400EX Fourtrax / Honda Motor Co., Ltd
Production year(s): 1999 2000, 2001, 2002
1999-2002 Honda TRX 400EX Fourtrax ATV service manual
Models covered in this manual:
File specifications
File type: ZIP
Language: English (some of our manuals are multi-language)
Printable: Yes
Estimated download time: 2.48 Minutes
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Product Information
Table of Contents
GENERAL INFORMATION
- General Safety
- 1-1
- Service Rules
- 1-2
- Model Identification
- 1-3
- Specifications
- 1-4
- Torque Values
- 1-14
- Tools
- 1-14
- Lubrication & Seal Points
- 1-16
- Cable & Harness Routing
- 1-18
- Emission Control Systems
- 1-22
- Emission Control Information
- 1-24
FRAME/BODY PANELS/EXHAUST SYSTEM
- Frame
- Inspection and Repair
- 2-1
- Body Panels
- Removal and Installation
- 2-5
- Exhaust System
- Inspection and Replacement
- 2-10
MAINTENANCE
- Maintenance Schedule
- Regular Maintenance Intervals
- 3-1
- Pre-ride Inspection
- Checklist Before Riding
- 3-3
- Lubrication Points
- Lubrication Requirements
- 3-5
LUBRICATION SYSTEM
- Engine Oil
- Types and Specifications
- 4-1
- Oil Filter
- Replacement Procedure
- 4-3
- Lubrication Circuit
- Diagram and Function
- 4-5
FUEL SYSTEM
- Fuel Tank
- Removal and Installation
- 5-1
- Fuel Pump
- Inspection and Testing
- 5-3
- Fuel Injectors
- Cleaning and Replacement
- 5-5
- Throttle Body
- Synchronization and Adjustment
- 5-7
ENGINE REMOVAL/INSTALLATION
- Engine Removal
- Step-by-step Procedure
- 6-1
- Engine Installation
- Step-by-step Procedure
- 6-10
CYLINDER HEAD/VALVE
- Cylinder Head Removal
- Procedure and Precautions
- 7-1
- Valve Inspection
- Valve Clearance and Adjustment
- 7-5
- Cylinder Head Installation
- Procedure and Precautions
- 7-10
CYLINDER/PISTON
- Cylinder Removal
- Step-by-step Procedure
- 8-1
- Piston Inspection
- Wear and Damage Check
- 8-5
- Cylinder Installation
- Step-by-step Procedure
- 8-10
CLUTCH/GEARSHIFT LINKAGE
- Clutch Removal
- Step-by-step Procedure
- 9-1
- Clutch Inspection
- Wear and Damage Check
- 9-5
- Clutch Installation
- Step-by-step Procedure
- 9-10
- Gearshift Linkage
- Inspection and Adjustment
- 9-15
ALTERNATOR/STARTER CLUTCH
- Alternator Removal
- Step-by-step Procedure
- 10-1
- Alternator Inspection
- Testing and Maintenance
- 10-5
- Alternator Installation
- Step-by-step Procedure
- 10-10
- Starter Clutch
- Inspection and Maintenance
- 10-15
CRANKCASE/TRANSMISSION
- Crankcase Disassembly
- Procedure and Precautions
- 11-1
- Transmission Inspection
- Gear and Shaft Check
- 11-5
- Crankcase Assembly
- Procedure and Precautions
- 11-10
CRANKSHAFT/PISTON/CYLINDER
- Crankshaft Removal
- Step-by-step Procedure
- 12-1
- Piston Inspection
- Wear and Damage Check
- 12-5
- Cylinder Inspection
- Wear and Damage Check
- 12-10
- Crankshaft Installation
- Step-by-step Procedure
- 12-15
FRONT WHEEL/SUSPENSION/STEERING
- Front Wheel Removal
- Procedure and Precautions
- 13-1
- Front Suspension Inspection
- Fork and Shock Absorber
- 13-5
- Steering Inspection
- Handlebar and Stem
- 13-10
REAR WHEEL/SUSPENSION
- Rear Wheel Removal
- Procedure and Precautions
- 14-1
- Rear Suspension Inspection
- Swingarm and Shock Absorber
- 14-5
HYDRAULIC DISC BRAKE
- Brake System Overview
- Components and Operation
- 15-1
- Front Brake Inspection
- Pad and Disc Check
- 15-5
- Rear Brake Inspection
- Pad and Disc Check
- 15-10
- Brake Fluid Replacement
- Procedure and Precautions
- 15-15
BATTERY/CHARGING SYSTEM
- Battery Maintenance
- Inspection and Charging
- 16-1
- Charging System Inspection
- Alternator and Regulator
- 16-5
IGNITION SYSTEM
- Ignition Coil
- Testing and Replacement
- 17-1
- Spark Plug
- Inspection and Replacement
- 17-5
- Ignition Timing
- Adjustment Procedure
- 17-10
ELECTRIC STARTER
- Starter Motor
- Removal and Inspection
- 18-1
- Starter Relay
- Testing and Replacement
- 18-5
LIGHTS/SWITCHES
- Headlight
- Bulb Replacement
- 19-1
- Tail/Brake Light
- Bulb Replacement
- 19-5
- Turn Signals
- Bulb Replacement
- 19-10
- Meter Panel
- Inspection and Replacement
- 19-15
- Switches
- Testing and Replacement
- 19-20
WIRING DIAGRAM
- Complete Wiring Diagrams
- Overview and Details
- 20-1
TROUBLESHOOTING
- Engine Troubleshooting
- Common Issues and Solutions
- 21-1
- Electrical Troubleshooting
- Common Issues and Solutions
- 21-10
- Chassis Troubleshooting
- Common Issues and Solutions
- 21-20
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