1999-2002 Honda TRX 400EX Fourtrax ATV service manual

1999-2002 Honda TRX 400EX Fourtrax ATV service manual Preview image 1
1999-2002 Honda TRX 400EX Fourtrax ATV service manual Preview image 1
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Models Covered in this Manual

TRX 400EX Fourtrax / Honda Motor Co., Ltd

Production year(s): 1999 2000, 2001, 2002

Product Information

Table of Contents

GENERAL INFORMATION

  1. General Safety
    • 1-1
  2. Service Rules
    • 1-2
  3. Model Identification
    • 1-3
  4. Specifications
    • 1-4
  5. Torque Values
    • 1-14
  6. Tools
    • 1-14
  7. Lubrication & Seal Points
    • 1-16
  8. Cable & Harness Routing
    • 1-18
  9. Emission Control Systems
    • 1-22
  10. Emission Control Information
    • 1-24

FRAME/BODY PANELS/EXHAUST SYSTEM

  1. Frame
    • Inspection and Repair
    • 2-1
  2. Body Panels
    • Removal and Installation
    • 2-5
  3. Exhaust System
    • Inspection and Replacement
    • 2-10

MAINTENANCE

  1. Maintenance Schedule
    • Regular Maintenance Intervals
    • 3-1
  2. Pre-ride Inspection
    • Checklist Before Riding
    • 3-3
  3. Lubrication Points
    • Lubrication Requirements
    • 3-5

LUBRICATION SYSTEM

  1. Engine Oil
    • Types and Specifications
    • 4-1
  2. Oil Filter
    • Replacement Procedure
    • 4-3
  3. Lubrication Circuit
    • Diagram and Function
    • 4-5

FUEL SYSTEM

  1. Fuel Tank
    • Removal and Installation
    • 5-1
  2. Fuel Pump
    • Inspection and Testing
    • 5-3
  3. Fuel Injectors
    • Cleaning and Replacement
    • 5-5
  4. Throttle Body
    • Synchronization and Adjustment
    • 5-7

ENGINE REMOVAL/INSTALLATION

  1. Engine Removal
    • Step-by-step Procedure
    • 6-1
  2. Engine Installation
    • Step-by-step Procedure
    • 6-10

CYLINDER HEAD/VALVE

  1. Cylinder Head Removal
    • Procedure and Precautions
    • 7-1
  2. Valve Inspection
    • Valve Clearance and Adjustment
    • 7-5
  3. Cylinder Head Installation
    • Procedure and Precautions
    • 7-10

CYLINDER/PISTON

  1. Cylinder Removal
    • Step-by-step Procedure
    • 8-1
  2. Piston Inspection
    • Wear and Damage Check
    • 8-5
  3. Cylinder Installation
    • Step-by-step Procedure
    • 8-10

CLUTCH/GEARSHIFT LINKAGE

  1. Clutch Removal
    • Step-by-step Procedure
    • 9-1
  2. Clutch Inspection
    • Wear and Damage Check
    • 9-5
  3. Clutch Installation
    • Step-by-step Procedure
    • 9-10
  4. Gearshift Linkage
    • Inspection and Adjustment
    • 9-15

ALTERNATOR/STARTER CLUTCH

  1. Alternator Removal
    • Step-by-step Procedure
    • 10-1
  2. Alternator Inspection
    • Testing and Maintenance
    • 10-5
  3. Alternator Installation
    • Step-by-step Procedure
    • 10-10
  4. Starter Clutch
    • Inspection and Maintenance
    • 10-15

CRANKCASE/TRANSMISSION

  1. Crankcase Disassembly
    • Procedure and Precautions
    • 11-1
  2. Transmission Inspection
    • Gear and Shaft Check
    • 11-5
  3. Crankcase Assembly
    • Procedure and Precautions
    • 11-10

CRANKSHAFT/PISTON/CYLINDER

  1. Crankshaft Removal
    • Step-by-step Procedure
    • 12-1
  2. Piston Inspection
    • Wear and Damage Check
    • 12-5
  3. Cylinder Inspection
    • Wear and Damage Check
    • 12-10
  4. Crankshaft Installation
    • Step-by-step Procedure
    • 12-15

FRONT WHEEL/SUSPENSION/STEERING

  1. Front Wheel Removal
    • Procedure and Precautions
    • 13-1
  2. Front Suspension Inspection
    • Fork and Shock Absorber
    • 13-5
  3. Steering Inspection
    • Handlebar and Stem
    • 13-10

REAR WHEEL/SUSPENSION

  1. Rear Wheel Removal
    • Procedure and Precautions
    • 14-1
  2. Rear Suspension Inspection
    • Swingarm and Shock Absorber
    • 14-5

HYDRAULIC DISC BRAKE

  1. Brake System Overview
    • Components and Operation
    • 15-1
  2. Front Brake Inspection
    • Pad and Disc Check
    • 15-5
  3. Rear Brake Inspection
    • Pad and Disc Check
    • 15-10
  4. Brake Fluid Replacement
    • Procedure and Precautions
    • 15-15

BATTERY/CHARGING SYSTEM

  1. Battery Maintenance
    • Inspection and Charging
    • 16-1
  2. Charging System Inspection
    • Alternator and Regulator
    • 16-5

IGNITION SYSTEM

  1. Ignition Coil
    • Testing and Replacement
    • 17-1
  2. Spark Plug
    • Inspection and Replacement
    • 17-5
  3. Ignition Timing
    • Adjustment Procedure
    • 17-10

ELECTRIC STARTER

  1. Starter Motor
    • Removal and Inspection
    • 18-1
  2. Starter Relay
    • Testing and Replacement
    • 18-5

LIGHTS/SWITCHES

  1. Headlight
    • Bulb Replacement
    • 19-1
  2. Tail/Brake Light
    • Bulb Replacement
    • 19-5
  3. Turn Signals
    • Bulb Replacement
    • 19-10
  4. Meter Panel
    • Inspection and Replacement
    • 19-15
  5. Switches
    • Testing and Replacement
    • 19-20

WIRING DIAGRAM

  1. Complete Wiring Diagrams
    • Overview and Details
    • 20-1

TROUBLESHOOTING

  1. Engine Troubleshooting
    • Common Issues and Solutions
    • 21-1
  2. Electrical Troubleshooting
    • Common Issues and Solutions
    • 21-10
  3. Chassis Troubleshooting
    • Common Issues and Solutions
    • 21-20

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