2005-2009 Honda TRX400EX Service Manual
This service manual covers the TRX400EX for 2005-2009, including general information, technical features, maintenance, and engine-related systems. PN C4256-90954.
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Models Covered & Key Technical Specifications
Honda TRX400EX (2005-2009) (C4256-90954) - 2005-2009 Service Manual | Engine Section.
- Engine Oil Capacity: 1.8 liters (1.9 US qt, 1.6 Imp qt) defines the recommended fluid volume for proper operation.
- Throttle Free Play: For optimal throttle response, 3 – 8 mm (1/8 – 5/16 in) controls the cable slack.
- Engine Dry Weight: 42.5 kg (93.7 lbs) represents the total mass of the engine assembly.
- Rear Wheel/Suspension Specs: The suspension system requires 30 – 40 mm (1 – 1.5 in) for optimal travel and stability.
- Primary Reduction Gear Ratio: 2.756 (14/39) establishes the gear reduction for efficient power transfer.
- Ignition System Specs: AC-CDI ignition system ensures reliable spark delivery for combustion.
Professional Workshop Service Manual & Technical Specifications
Honda TRX400EX (2005-2009) Service Manual: Engine-Compendium
Diagnostic-Area: TRX400EX (2005-2009) // Application-Range: ATV / Engine Logic // Diagnostic-Area: Technical Manual.
| Service-Nexus | Operational-Logic | Calibration-Standards |
|---|---|---|
| General Information | Maintenance | Specifications |
| Engine Removal/Installation | Lubrication System | Cylinder Head/Valve |
| Cylinder/Piston | Clutch/Gearshift Linkage | Alternator/Starter Clutch |
| Fuel System | Troubleshooting | Troubleshooting |
Service procedures are grouped by system, covering engine removal and installation, lubrication, and various engine components. It includes detailed specifications for parts and systems, ensuring accurate maintenance and repair. Key systems such as the fuel system, ignition, and electrical components are thoroughly documented. The manual also provides comprehensive troubleshooting guidance for common issues. Effectively requiring accurate assembly, this document details procedures for engine disassembly, torque specifications for critical fasteners, and component measurements to ensure proper operation and joint separation prevention.
This manual documents torque specifications for critical engine components to ensure proper joint separation prevention.
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