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TRX400FW
Service manual
Honda TRX400FW Service Manual
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Table Of Contents
371
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Important Safety Notice
Contents
General Information: Contents
General Safety
Service Rules
Model Identification
Specifications - General
Specifications - Lubrication/Fuel System
Specifications - Cylinder Head/Valves/Camshaft/Piston
Specifications - Clutch/Gearshift Linkage
Specifications - Crankshaft/Transmission
Specifications - Front/Rear Wheel/Suspension/Steering/Brakes/Front Driving Mechanism
Specifications - Rear Driving Mechanism, Battery/Charging System, Ignition System, Electric Starter
Specifications - Light/Switches
Torque Values
Tools
Lubrication and Seal Point
Cable and Harness Routing
Frame/Body Panels/Exhaust System: Contents, Service Information, Troubleshooting
Body Panel Locations
Seat/Side Cover Removal
Seat/Side Cover Installation
Front Carrier/Bumper/Front Fender Removal
Front Carrier/Bumper/Front Fender Disassembly
Rear Carrier/Rear Fender Removal
Rear Carrier/Rear Fender Disassembly
Rear Carrier/Rear Fender Installation
Handlebar Cover Removal
Handlebar Cover Installation
Exhaust System Removal
Muffler
Exhaust System Installation
Maintenance: Contents, Service Information
Maintenance Schedule
Fuel Line
Throttle Operation
Carburetor Choke
Air Cleaner
Air Cleaner Housing Drain Tube
Spark Plug
Valve Clearance
Engine Oil and Oil Filter
Oil Level Inspection
Engine Oil and Filter Change
Engine Idle Speed
Final Gear Case Oil and Differential Oil
Oil Change
Brake Fluid
Brake Shoe Wear
Brake System
Reverse Lock System
Skid Plates/Engine Guard
Clutch System
Drive Shaft Boots Inspection
Suspension
Spark Arrester: Cleaning
Nuts, Bolts, Fasteners
Wheels/Tires
Steering Shaft Holder Bearing
Steering System
Toe
Lubrication System Diagram
Lubrication System: Contents, Service Information, Troubleshooting
Oil Cooler Removal, Disassembly, Inspection
Oil Cooler Assembly, Installation
Cooling Fan Motor/Shroud Removal
Cooling Fan Motor/Shroud Disassembly
Cooling Fan Motor/Shroud Assembly
Cooling Fan Motor/Shroud Installation
Oil Pump Removal/Disassembly, Inspection
Oil Pump Assembly
Oil Pump Installation
Relfief Valve Disassembly, Inspection, Assembly
Oil Strainer Screen Cleaning
Fuel System: Contents, Service Information
Fuel System: Specifications
Fuel System: Troubleshooting
Air Cleaner Housing Removal, Installation
Carburetor Removal
Carburetor Disassembly
Starting Enrichment Valve
Float and Jets
Primer Knob
Diaphragm/Vacuum Piston
Air Cut off Valve
Carburetor Assembly
Float Level Inspection
Carburetor Installation
Starting Enrichement Valve
Pilot Screw Adjustment
High Altitude Adjustment
Fuel Tank Removal
Fuel Strainer Screen
Fuel Tank Installation
Engine Removal/Installation: Contents, Service Information
Engine Removal
Engine Installation
Cylinder Head/Cylinder/Piston: Contents, Service Information
Cylinder Head/Cylinder/Piston: Troubleshooting
Cylinder Compression Test
Cylinder Head Removal/Cover Removal
Cylinder Head Removal
Rocker Arm Holder Disassembly/Inspection
Cylinder Head Disassembly, Inspection
Valve Spring
Valve/Valve Guide
Valve Guide Replacement
Valve Seat Inspection/Refacing
Valve Seat Refacing
Cylinder Head Assembly
Cylinder Head Installation
Rocker Arm Holder Assembly
Rocker Arm Holder Installation
Cylinder/Piston Removal
Cylinder/Piston Inspection
Cylinder/Piston Installation
Camshaft/Cam Chain Tensioner
Cam Chain Tensioner Removal
Cam Chain Tensioner Inspection
Cam Chain Tensioner Installation
Camshaft Installation
Cam Chain Tensioner Lifter
Clutch: Contents, Service Information
Clutch: Troubleshooting
Front Crankcase Cover Removal
Bearing Replacement
Centrifugal Clutch/Primary Drive Gear Removal
Centrifugal Clutch/Primary Drive Gear Inspection
Centrifugal Clutch/Primary Drive Gear Assembly
Centrifugal Clutch/Primary Drive Gear Installation
Change Clutch Removal
Change Clutch Inspection
Change Clutch Installation
Front Crankcase Cover Installation
Gearshift Linkage: Contents, Service Information, Troubleshooting
Gearshift Linkage Removal
Gearshift Linkage Inspection, Installation
Reverse Stopper Shaft Removal
Alternator/Starter Clutch
Alternator/Starter Clutch: Contents, Service Information, Troubleshooting
Recoil Starter Removal, Disassembly
Recoil Starter Assembly
Recoil Starter Installation
Alternator Removal
Alternator Cover Disassembly
Flywheel/Starter Clutch Removal
Rear Crankcase Cover Removal
Starter Clutch Inspection/Disassembly
Starter Clutch Assembly
Rear Crankcase Cover Installation
Flywheel/Starter Clutch Installation
Alternator Installation/Assembly
Crankshaft/Balancer/Transmission Overview
Crankshaft/Balancer/Transmission: Contents, Service Information
Crankshaft/Balancer/Transmission: Troubleshooting
Crankcase Separation
Transmission Removal/Disassembly
Crankcase Bearing Locations
Reverse Idle Shaft
Crankshaft/Balancer Removal
Crankshaft/Balancer Inspection
Crankshaft/Balancer Installation
Crankcase Assembly
Front Wheel/Suspension/Steering: Contents, Service Information
Front Wheel/Suspension/Steering: Troubleshooting
Handlebar Removal/Installation
Throttle Housing Disassembly
Throttle Housing Assembly
Front Wheel Removal/Installation
Tires Removal
Tire Repair
Tire Assembly
Tie-Rod/Knuckle Removal
Tie-Rod/Knuckle Inspection
Knuckle Bearing Inspection/Replacement
Knuckle Installation
Tie-Rod Assembly, Installation
Upper/Lower Arms Removal, Inspection
Upper/Lower Arms Installation
Steering Shaft Removal
Steering Shaft Inspection
Steering Shaft Installation
Front Shock Absorber Removal, Disassembly, Inspection
Front Shock Absorber Assembly
Front Shock Absorber Installation
Rear Wheel/Suspension: Overview
Rear Wheel/Suspension: Contents, Service Information
Rear Wheel/Suspension: Troubleshooting
Rear Wheel Removal, Installation
Rear Shock Absorber Removal
Rear Shock Absorber Disassembly, Inspection
Rear Shock Absorber Assembly
Rear Shock Absorber Installation
Swingarm Removal
Swingarm Inspection
Pivot Bearing Replacement
Swingarm Installation
Brake System Overview
Brake System: Contents, Service Information
Brake System: Troubleshooting
Brake Fluid Replacement/Air Bleeding
Brake Fluid Draining
Brake Bleeding
Brake Hose/Brake Pipe/Breather Tube Inspection
Master Cylinder Disassembly
Master Cylinder Inspection/Assembly
Brake Shoes/Wheel Cylinder/Adjuster Disassembly
Wheel Cylinder/Adjuster Inspection
Front Brake Panel Inspection
Front Brake Waterproof Seal Inspection/Replacement
Front Brake Waterproof Seal Assembly
Rear Brake Removal/Disassembly
Rear Brake Assembly/Installation
Brake Pedal Removal/Installation
Front Driving Mechanism Overview
Front Driving Mechanism: Contents, Service Information
Front Driving Mechanism: Troubleshooting
Front Drive Shaft Removal
Front Drive Shaft Inspection/Disassembly
Front Drive Shaft Assembly
Front Drive Shaft Installation
Front Differential Removal
Backlash/Front Differential Inspection
Differential Case Disassembly
Gear Tooth Contact Pattern Check
Differential Assembly Inspection
Differential Disassembly
Differential Inspection
Drive Pinion Removal
Drive Pinion Disassembly/Assembly
Case Bearing Replacement
Drive Pinion Installation
Differential Assembly
Differential Case Assembly/Installation
Rear Driving Mechanism Overview
Rear Driving Mechanism: Contents, Service Information
Rear Driving Mechanism: Troubleshooting
Rear Axle Removal
Rear Axle Inspection
Rear Final Drive
Gear Case Removal/Inspection
Backlash Inspection
Gear Case Disassembly
Gear Tooth Pattern Check
Gear Case Assembly Overview
Gear Case Installation
Rear Axle Installation
Rear Drive Shaft Removal/Inspection/Installation
Battery/Charging System Overview
Battery/Charging System: Contents, Service Information
Battery/Charging System Troubleshooting
Battery Removal/Installation
Voltage Inspection
Battery Testing
Battery Charging
Charging System
Leakage/Regulated Voltage Inspection
Alternator Charging Coil Inspection
Regulator/Rectifier: Voltage Inspection
Regulator/Rectifier Replacement
Ignition System: Overview
Ignition System: Contents, Service Information
Ignition System Troubleshooting
Ignition System Inspection
Ignition Primary Peak Voltage
Ignition Pulse Generator Peak Voltage
AC Sensor Line Inspection
Ignition Coil Inspection
Ignition Coil Removal/Installation
Ignition Pulse Generator Inspection/Removal/Installation
Ignition Timing
Electric Starter Overview
Electric Starter: Contents, Service Information
Electric Starter: Troubleshooting
Starter Motor Removal/Disassembly/Inspection
Starter Motor Assembly
Starter Motor Installation
Starter Relay Switch: Operation Inspection
Voltage/Continuity Inspection
Diode Removal/Inspection/Installation
Lights/Switches: Overview
Lights/Switches: Contents, Service Information, Troubleshooting
Headlight Bulb Replacement
Headlight Bulb Removal/Installation
Assist Headlight: Bulb Replacement
Taillight Bulb Replacement/Removal/Installation
Indicator Lamps Bulb Replacement
Ignition Switch Inspection
Handlebar Switches
Neutral/Reverse Switch Inspection
Neutral/Reverse Switch Removal/Installation
Cooling Fan Control Unit: System Inspection
Oil Thermo Sensor Inspection/Removal/Installation
Wiring Diagram
Technical Feature
Power Train
Limited Slip Differential
OHV Valve Train
Gearshift Mechanism
Troubleshooting
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Table of
Contents
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Table of Contents
Troubleshooting
Frame/Body Panels/Exhaust System: Contents, Service Information, Troubleshooting
31
Lubrication System: Contents, Service Information, Troubleshooting
67
Fuel System: Troubleshooting
83
Cylinder Head/Cylinder/Piston: Troubleshooting
113
Clutch: Troubleshooting
140
Gearshift Linkage: Contents, Service Information, Troubleshooting
159
Alternator/Starter Clutch: Contents, Service Information, Troubleshooting
169
Crankshaft/Balancer/Transmission: Troubleshooting
187
Front Wheel/Suspension/Steering: Troubleshooting
204
Rear Wheel/Suspension: Troubleshooting
232
Brake System: Troubleshooting
244
Front Driving Mechanism: Troubleshooting
270
Rear Driving Mechanism: Troubleshooting
298
Battery/Charging System Troubleshooting
321
Ignition System Troubleshooting
331
Electric Starter: Troubleshooting
340
Lights/Switches: Contents, Service Information, Troubleshooting
349
Troubleshooting
365
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