Sign In
Upload
Download
Table of Contents
Contents
Add to my manuals
Delete from my manuals
Share
URL of this page:
HTML Link:
Bookmark this page
Add
Manual will be automatically added to "My Manuals"
Print this page
×
Bookmark added
×
Added to my manuals
Manuals
Brands
Honda Manuals
Offroad Vehicle
TRX400FW
Service manual
Honda TRX400FW Service Manual
Hide thumbs
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
Table Of Contents
371
page
of
371
Go
/
371
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
Advertisement
Quick Links
Download this manual
Table of
Contents
Previous
Page
Next
Page
1
2
3
4
5
Advertisement
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
Need help?
Do you have a question about the TRX400FW and is the answer not in the manual?
Ask a question
Questions and answers
Related Manuals for Honda TRX400FW
Offroad Vehicle Honda 1995 TRX 400 FW Owner's Manual
Fourtrax foreman 400 (155 pages)
Offroad Vehicle Honda TRX400FA Owner's Manual
Fourtrax rancher at/with gpscape (287 pages)
Offroad Vehicle Honda TRX400FA Service Manual
2004-2007 (514 pages)
Offroad Vehicle Honda TRX400FA FourTrax AT Owner's Manual
(235 pages)
Offroad Vehicle Honda TRX400FW Foreman 400 Owner's Manual
Fourtrax foreman 400 (165 pages)
Offroad Vehicle Honda Fourtrax Foreman TRX400FW 1997 Owner's Manual
(163 pages)
Offroad Vehicle Honda TRX400FA 2004 Service Manual
(514 pages)
Offroad Vehicle Honda TRX400FA 2005 Owner's Manual
Fourtrax rancher at/with gpscape (285 pages)
Offroad Vehicle Honda Fourtrax Rancher AT 2004 Service Manual
(514 pages)
Offroad Vehicle Honda TRX400FGA 2004 Service Manual
(514 pages)
Offroad Vehicle Honda TRX400FA 2007 Service Manual
(514 pages)
Offroad Vehicle Honda TRX400FGA 2007 Service Manual
(514 pages)
Offroad Vehicle Honda TRX400EX 2008 Owner's Manual
(241 pages)
Offroad Vehicle Honda TRX400EX SportTrax 400EX Owner's Manual
(221 pages)
Offroad Vehicle Honda TRX400EX FOURTRAX 1999 Service Manual
(264 pages)
Offroad Vehicle Honda TRX400X Owner's Manual
(248 pages)
Related Products for Honda TRX400FW
Honda 1995 TRX 400 FW
Honda TRX400FGA
Honda TRX400FA
Honda TRX400FW Foreman 400
Honda Fourtrax Foreman TRX400FW 1997
Honda TRX400 FA 2004 fourtrax rancher
Honda TRX400 FGA 2004 fourtrax rancher
Honda TRX400 FA 2005 fourtrax rancher
Honda TRX400 FA 2006 fourtrax rancher
Honda TRX400 FA 2007 fourtrax rancher
Honda TRX400 FA 2007 fourtrax ranche
Honda TRX400FA 2005
Honda TRX400FGA 2005
Honda TRX400FGA 2004
Honda TRX400FA 2007
Honda TRX400FGA 2007
Table of Contents
Save PDF
Print
Rename the bookmark
Delete bookmark?
Delete from my manuals?
Login
Sign In
OR
Sign in with Facebook
Sign in with Google
Upload manual
Upload from disk
Upload from URL
Need help?
Do you have a question about the TRX400FW and is the answer not in the manual?
Questions and answers