Honda TRX400EX FOURTRAX 1999 Manuals

Honda TRX400EX FOURTRAX 1999 Manuals

Manuals and User Guides for Honda TRX400EX FOURTRAX 1999. We have 1 Honda TRX400EX FOURTRAX 1999 manual available for free PDF download: Service Manual

Honda TRX400EX FOURTRAX 1999 Service Manual

Honda TRX400EX FOURTRAX 1999 Service Manual (264 pages)

Brand: Honda | Category: Offroad Vehicle | Size: 129.12 MB

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
  - Throеtle 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

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