2005-2009 Honda TRX400EX Service Manual

2005–2009 Honda TRX400EX Service Manual Coverage

• Covers 2005–2009 Honda TRX400EX and TRX400X models including U.S.A., Canada, and Australian regional variants
• Original Honda publication C4256-90954, full technical documentation for the TRX400 series
• Contains 82 exploded-view diagrams, 27 torque tables, and full color-coded wiring schematic sections
• Full-text search finds any part number in seconds
• OCR text layer lets you jump to a torque spec by keyword
• This 345-page official workshop manual provides the necessary specification data for major engine, chassis, and electrical maintenance on all 2005–2009 Honda TRX400EX units

Technical Documentation and System Overview

This 345-page official Honda workshop manual details the structural and operational parameters for the 2005–2009 Honda TRX400EX and TRX400X. It covers the air-cooled 397 cc engine assembly, including the piston, cylinder, valve train, and five-speed transmission. System-specific chapters describe the carburetor disassembly, clutch system, and lubrication system architecture. The document also details the chassis, encompassing the front and rear suspension, steering geometry, and hydraulic disc braking components. Electrical sections map the AC-CDI ignition system, charging circuit, and lighting configurations. Additional sections provide guidance for frame, exhaust, and body panel maintenance.

Specifications and Reference Values

Technical data is presented throughout the document via extensive specification tables and exploded-view illustrations. Engine oil capacity is documented at 1.8 liters for draining, while fuel tank volume is specified at 10 liters. The manual includes a comprehensive workshop manual approach to component tolerances and torque requirements. Mainjet size is listed as #148 with a #38 slow jet for standard carburetor operation. Torque for the cylinder head nut is specified at 44 Nm (32 lbf-ft) in the assembly data. Intake valve clearance is set at 0.10 mm, and the exhaust valve clearance is listed at 0.12 mm in the cylinder head specification table. Reference is provided for checking drive chain slack at 30–40 mm. This 345-page official Honda manual is the primary reference for servicing the 2005–2009 Honda TRX400EX, documenting essential engine, chassis, and electrical specifications for the entire production range. Reference only — always consult a certified technician before performing service on this equipment.