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TRX400EX FOURTRAX 1999
Honda TRX400EX FOURTRAX 1999 User Manual
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2
Table of Contents
Contents
3
Symbols
4
General Information
5
General Safety
5
Table of Contents
5
Carbon Monoxide
5
Used Engine Oil
5
Service Rules
6
Model Identification
7
Specifications
8
Torque Values
15
Tools
18
General Information
18
Lubrication & Seal Points
20
Cable & Harness Routing
22
Crankcase Emission Control System
27
Exhaust Emission Control System
27
Source of Emissions
27
Emission Control Information Label
28
Excessive Exhaust Noise
29
Frame/Body Panels/Exhaust System
29
Poor Performance
29
Service Information
29
Front Fender
30
Seat/Rear Fender
30
Side Cover
31
Fuel Tank
32
Fuel Tank & Heat Protector
32
Tank under Heat Protector
32
Footpeg/Mud Guard
33
Skid Plate
33
Exhaust Pipe
34
Exhaust System
34
Muffler
34
Maintenance
35
Maintenance Schedule
37
Note
37
Fuel Line
38
Throttle Operation
38
Air Cleaner
39
Air Cleaner Housing Drain Tube
40
Spark Plug
40
Valve Clearance
41
Engine Oil
43
Level Check
43
Oil Viscosities
43
Recommended Engine Oil
43
Oil Change
44
Oil Check Bolt and Sealing Washer
44
Engine Oil Filter
45
Engine Idle Speed
46
Engine Oil Strainer Screen in Oil Tank
46
Chain Slack Inspection
47
Cleaning and Inspection
47
Drive Chain
47
Lubrication
47
Brake Fluid
48
Drive Chain Slider
48
Front Brake
48
Sprocket Inspection
48
Brake Pads Wear
49
Inspection for Air in System
49
Rear Brake
49
Brake Lock Cable Adjustment
50
Brake Pedal Height
50
Clutch System
51
Skid Plate, Engine Guard
51
Suspension
52
Nuts, Bolts, Fasteners
53
Spark Arrester
53
Wheels / Tires
53
Steering Shaft Holder Bearing
54
Steering System
54
Lubrication System
57
Oil Contamination
57
Oil Level too Low-High Oil Consumption
57
Oil Pump & Strainer
58
Relief Valve Check
58
Inspection
59
Oil Strainer Cleaning
60
Oil Cooler & Oil Tank
62
Oil Cooler
63
Oil Pipes
63
Oil Tank
63
Fuel System
65
Backfiring or Misfiring During Acceleration
66
Engine Cranks but Won't Start
66
Lean Mixture
66
Pilot Screw Wrench
66
Rich Mixture
66
Troubleshooting
66
Air Cut-Off Valve
67
Carburetor Disassembly/ Inspection
67
Carburetor Removal
67
Throttle Valve
68
Accelerator Pump
69
Float and Jets
69
Carburetor Assembly
71
Carburetor Cleaning
71
Fuel System
71
Float Level Inspection
72
ThroŠµtle Valve
73
Carburetor Installation
76
Final Opening
77
Idle Drop Procedure
77
Idle Speed
77
Pilot Screw Adjustment
77
High Altitude Adjustment
78
High Altitude Pilot Screw Opening
78
Standard Main Jet
78
Air Cleaner Housing
79
Engine Removal/Installation
80
Engine Removal
82
Engine Installation
84
Cylinder Head/Valve
86
Compression too High
88
Excessive Noise
88
Excessive Smoke
88
Troubleshooting
88
Cylinder Compression
89
Cylinder Head Cover/Camshaft Removal
89
Camshaft
92
Cylinder Head Cover Disassembly
92
Decompressor Disassembly
93
Rocker Arm/Shaft
93
Decompressor Assembly
94
Cylinder Head Removal/ Disassembly
95
Valve Stem/Valve Guide
97
Valve Guide Replacement
98
Valve Seat Inspection/Refacing
99
Cylinder Head Assembly/ Installation
102
Camshaft/Cylinder Head Cover Installation
104
Cylinder/Piston
113
Abnormal Noise
114
Compression too High, Overheating or Knocking
114
Cylinder Removal
115
Piston Removal
115
Cylinder
116
Piston/Piston Ring
117
Piston Ring Installation
119
Cylinder Installation
120
Clutch/Gearshift Linkage
123
Clutch Lever too Hard
124
Clutch Slips
124
Hard to Shift
124
Transmission Jumps out of Gear
124
Right Crankcase Cover Removal
125
Clutch
127
Clutch Spring
128
Lifter Bearing
128
Clutch Center
129
Clutch Disc
129
Clutch Outer/Outer Guide
129
Clutch Plate
129
Mainshaft
130
Primary Drive Gear
132
Gearshift Linkage
133
Alternator/Starter Clutch
134
Alternator Stator
136
Left Crankcase Cover Removal
136
Stator Removal/Installation
137
Left Crankcase Cover Installation
138
Flywheel Removal
139
Starter Clutch
140
Flywheel Installation
142
Crankcase/Transmission/Crankshaft
145
Abnormal Vibration
146
Excessive Engine Noise
146
Crankcase Separation
147
Transmission
148
Bearing Remover, 15 MM
156
Crankcase Assembly
159
Front Wheel/Suspension/Steering
163
Assembly Collar
164
Hard Steering
164
Hard Suspension
164
Soft Suspension
164
Steers One Side or Does Not Track Straight
164
Handlebar
165
Note
166
Throttle Housing
167
Front Wheel and Hub
168
Hub Disassembly
168
Wheel Removal
168
Note
169
Tires
171
Wheel Installation
171
Tire Repair
173
Front Shock Absorber
178
Steering Shaft and Tie-Rod
179
Rear Wheel/Suspension
185
Rear Suspension Noise
186
Rear Wheel Turns Hard
186
Rear Wheel Wobbling
186
Rear Axle
187
Rear Wheel
187
Rear Shock Absorber
193
Bearing Replacement
194
Shock Linkage
195
Hydraulic Disc Brake
200
Brake Drag
202
Brake Leverlpedal Hard
202
Brake Leverlpedal Soft or Spongy
202
Troubleshooting
202
Brake Fluid Draining
203
Brake Fluid Filling/Bleeding
203
Brake Fluid Replacement/ Air Bleeding
203
Brake Pad/Disc
205
Front Brake Pad Replacement
205
Rear Brake Pad Replacement
206
Brake Disc Inspection
207
Front Master Cylinder
207
Front Brake Caliper
210
Rear Master Cylinder
213
Rear Brake Caliper
216
Cable Lock Brake
217
Hydraulic Brake
217
Brake Pedal
220
Baltery/Charging SYSTEM
222
Battery Charging
224
Battery Is Damaged or Weak
225
Battery Charging
226
Voltage Inspection
226
Charging System Inspection
227
Charging Voltage Inspection
227
Current Leakage Test
227
Baltery LINE
228
Regulator/Rectifier
228
Voltage Feedback Line
228
Wire Harness Inspection
228
Alternator Charging Coil
229
Ignition System
231
Ignition Primary Peak Voltage
233
Ignition System Inspection
233
Peak Voltage
233
Exciter Coil Peak Voltage
234
Ignition Pulse Generator Peak Voltage
235
Ignition Coil
236
Ignition Control Module (ICM)
236
Ignition Timing
237
Electric Starter
239
Starter Motor will Not Turn
240
Troubleshooting
240
Electric Starter
242
Starter Motor
242
Ground Line
247
Starter Relay Switch
247
Clutch Diode
248
Operation Check
248
Starter Relay Voltage
248
Lights/Switches
250
Service Information General
251
Bulb Replacement
252
Headlight
252
Headlight Replacement
252
Taillight
252
Neutral Indicator
253
Ignition Switch
253
Handlebar Switch
254
Engine Stop Switch
254
Clutch Switch
254
Lighting Switch
254
Neutral Switch
255
Wiring Diagram
257
Engines Does Not Start or Is Hard to Start
258
Engine Lacks Power
259
Poor Performance at Low and Idle Speed
260
Poor Performance at High Speed
261
Poor Handling
261
Index
262
5
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Honda TRX400EX FOURTRAX 1999 Specifications
General
Brand
Honda
Model
TRX400EX FOURTRAX 1999
Category
Offroad Vehicle
Language
English
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