Honda TRX 400ex Manual
This Clymer ATV manual covers the Honda TRX400EX for these years:
1999, 2000, 2001, 2002, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013
TRX400EX Fourtrax (1999-2000)
TRX400EX Sportrax (2001-2013)
Clymer ATV repair manuals are the best reference book for repair and service information. Every service manual is written for the do-it-yourselfer as well as the experienced mechanic, Clymer repair manuals are the cheapest way to keep your four wheeler running properly. Every manual contains hundreds of original photographs and illustrations obtained from the complete disassembly and assembly of the ATV covered. This, in addition to extensive research, is how Clymer repair manuals achieve an unmatched level of detail, accuracy and clarity to guide the reader through each service, troubleshooting and repair procedure.
This Honda TRX400 Manual is 336 pages.
QUICK REFERENCE DATA
CHAPTER ONE / GENERAL INFORMATION
Manual organization / Basic service methods / Warnings, cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Basic tools / Precision measuring tools / Storage / Specifications Specs
CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Starting the engine / Engine spark test / Engine performance / Electrical testing / Engine starting system / Engine noise / Vehicle noise / Engine leakdown test / Clutch / Gear shift linkage and transmission / Brakes / Steering and handling / Specifications Specs
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride checklist / Engine break-in / Service intervals / Maintenance schedule / Oil and filter change / Engine oil tank strainer / Drive chain cleaning, lubrication and adjustment / Slider inspection / Throttle cable adjustment / Clutch adjustment / Fuel line and valve inspection / brake pad and disc inspection / Parking brake adjustment / Brake pedal adjustment / Brake bleeding / Skid plate / Muffler cleaning / Steering shaft inspection / Tie rod inspection / Shock inspection / Swing arm inspection / Valve clearance adjustment / Carburetor adjustment / Engine compression check / Engine timing / Spark plug / Specifications
CHAPTER FOUR / ENGINE TOP END
Cleanliness / Cylinder head cover / Camshaft, cam chain sprocket, and tensioner / Decompressor / Cylinder head / Valves and valve components / Cylinder / Piston and piston rings / Break-in
CHAPTER FIVE / ENGINE LOWER END
Shop cleanliness / Drive sprocket / Cam chain, sprocket and guides / Engine / Crankcase (1999-2004 models) / Crankcase seal and bearing replacement / Crankshaft / Engine break-in
CHAPTER SIX / CLUTCH, GEARSHIFT LINKAGE AND LUBRICATION SYSTEM
Right crankcase cover / Gearshift linkage / Primary drive gear / Oil pump / Crankcase oil strainer / Oil cooler / Oil tank / Specifications
CHAPTER SEVEN / TRANSMISSION AND INTERNAL SHIFT MECHANISM
Mainshaft / Countershaft / Shift drum and forks / Gearshift spindle and plate / Specifications
CHAPTER EIGHT / FUEL AND EXHAUST SYSTEMS
Air cleaner / Carburetor / Carb inspection, repair and adjustment / Throttle control and cable / Exhaust pipe and muffler / Specifications
CHAPTER NINE / ELECTRICAL SYSTEM
Left crankcase cover and stator / Flywheel / Starter clutch / Starter / Switches / Handlebar switch unit / Ignition system / Fuse / Charging system / Lights / Specifications
CHAPTER TEN / FRONT SUSPENSION
Front wheel / Front hub / Tie rods / Steering knuckle / Control arms / Shock absorbers / Steering shaft / Handlebar / Tires and wheels / Specifications
CHAPTER ELEVEN / REAR SUSPENSION
Rear wheel / Rear hub / Rear axle / Rear axle bearing holder / Driven sprocket / Drive chain / Shock absorber / Rear suspension adjustment / Shock linkage / Swing arm / Specifications
CHAPTER TWELVE / BRAKES
Disc brake fundamentals / Front brake pads / Front brake caliper / Front master cylinder / Rear brake pads / Rear brake caliper / Rear master cylinder / Brake pedal / Brake discs / Specifications
CHAPTER THIRTEEN / BODY
Seat / Rear Fender / Upper cover / Side covers / Handlebar cover / Fuel tank / Fuel tank heat protector / Foorpegs and mudguard / Tool box / Specifications
SUPPLEMENT / 2005-2012 MODEL SERVICE INFORMATION
Gear shift linkage and transmission / Periodic maintenance / Engine / Right crankcase cover / Reverse stopper plate / Transmission operation / Mainshaft / Countershaft / Reverse idle gear and shaft / Reverse switch / Taillight / Side covers / Upper headlight cover / Lower headlight cover / Front fenders
COLOR WIRING DIAGRAMS
The Honda 400ex manual contains the following:
- Handy thumb-tabs put the chapter you need right at your fingertips.
- Detailed substeps expand on service procedure information.
- Notes, cautions and warnings throughout each chapter pinpoint critical information.
- Numbered instructions guide you through every repair procedure step by step.
- Bold figure numbers help you quickly match illustrations with instructions.
- Detailed illustrations, drawings and photos guide you through every service procedure.
- Exploded views help you identify and examine parts in detail.
- Numbered table of contents . . . easy to use so that you can find the information you need fast.
- Clymer repair manuals also make it easy to diagnose and repair electrical system problems on your all terrain vehicle.
- Troubleshooting and electrical service procedures are combined with detailed wiring diagrams (color on select titles) for ease of use.
Honda 400ex Repair Manual
Honda 400ex Service Manual
Honda 400ex Shop Manual
Honda model name variations: trx400ex, 400 ex, trx 400 ex, trx400, fourtrax, four trax, sportrax, sport trax