Honda ATV TRX400EX Fourtrax / Sportrax & TRX400X 1999-2014 Online Manual (ECM454-5)

Honda ATV TRX400EX Fourtrax / Sportrax & TRX400X 1999-2014 Online Manual

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TRX400EX Fourtrax (1999-2000)
TRX400EX Sportrax (2001-2014)

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

INDEX

COLOR WIRING DIAGRAMS