Table Of Contents - Honda TRX400FW Service Manual

Table of Contents

Important Safety Notice2
Contents3
General Information: Contents5
General Safety5
Service Rules6
Model Identification7
Specifications - General8
Specifications - Lubrication/Fuel System10
Specifications - Cylinder Head/Valves/Camshaft/Piston11
Specifications - Clutch/Gearshift Linkage12
Specifications - Crankshaft/Transmission13
Specifications - Front/Rear Wheel/Suspension/Steering/Brakes/Front Driving Mechanism14
Specifications - Rear Driving Mechanism, Battery/Charging System, Ignition System, Electric Starter15
Specifications - Light/Switches16
Torque Values17
Tools20
Lubrication And Seal Point22
Cable And Harness Routing25
Frame/Body Panels/Exhaust System: Contents, Service Information, Troubleshooting31
Body Panel Locations32
Seat/Side Cover Removal33
Seat/Side Cover Installation34
Front Carrier/Bumper/Front Fender Removal35
Front Carrier/Bumper/Front Fender Disassembly36
Rear Carrier/Rear Fender Removal39
Rear Carrier/Rear Fender Disassembly40
Rear Carrier/Rear Fender Installation41
Handlebar Cover Removal42
Handlebar Cover Installation43
Exhaust System Removal43
Muffler43
Exhaust System Installation44
Maintenance: Contents, Service Information45
Maintenance Schedule47
Fuel Line48
Throttle Operation48
Carburetor Choke49
Air Cleaner49
Air Cleaner Housing Drain Tube50
Spark Plug51
Valve Clearance52
Engine Oil And Oil Filter53
Oil Level Inspection53
Engine Oil And Filter Change54
Engine Idle Speed55
Final Gear Case Oil And Differential Oil56
Oil Change57
Brake Fluid58
Brake Shoe Wear58
Brake System59
Reverse Lock System60
Skid Plates/Engine Guard61
Clutch System61
Drive Shaft Boots Inspection61
Suspension62
Spark Arrester: Cleaning62
Nuts, Bolts, Fasteners63
Wheels/Tires63
Steering Shaft Holder Bearing63
Steering System64
Toe64
Lubrication System Diagram66
Lubrication System: Contents, Service Information, Troubleshooting67
Oil Cooler Removal, Disassembly, Inspection68
Oil Cooler Assembly, Installation69
Cooling Fan Motor/Shroud Removal70
Cooling Fan Motor/Shroud Disassembly71
Cooling Fan Motor/Shroud Assembly72
Cooling Fan Motor/Shroud Installation73
Oil Pump Removal/Disassembly, Inspection74
Oil Pump Assembly76
Oil Pump Installation77
Relfief Valve Disassembly, Inspection, Assembly77
Oil Strainer Screen Cleaning78
Fuel System: Contents, Service Information81
Fuel System: Specifications82
Fuel System: Troubleshooting83
Air Cleaner Housing Removal, Installation84
Carburetor Removal85
Carburetor Disassembly86
Starting Enrichment Valve86
Float And Jets86
Primer Knob88
Diaphragm/Vacuum Piston88
Air Cut Off Valve89
Carburetor Assembly90
Float Level Inspection93
Carburetor Installation94
Starting Enrichement Valve94
Pilot Screw Adjustment96
High Altitude Adjustment97
Fuel Tank Removal98
Fuel Strainer Screen98
Fuel Tank Installation99
Engine Removal/Installation: Contents, Service Information103
Engine Removal104
Engine Installation106
Cylinder Head/Cylinder/Piston: Contents, Service Information111
Cylinder Head/Cylinder/Piston: Troubleshooting113
Cylinder Compression Test114
Cylinder Head Removal/Cover Removal114
Cylinder Head Removal115
Rocker Arm Holder Disassembly/Inspection116
Cylinder Head Disassembly, Inspection117
Valve Spring117
Valve/Valve Guide118
Valve Guide Replacement119
Valve Seat Inspection/Refacing119
Valve Seat Refacing120
Cylinder Head Assembly122
Cylinder Head Installation123
Rocker Arm Holder Assembly123
Rocker Arm Holder Installation124
Cylinder/Piston Removal125
Cylinder/Piston Inspection126
Cylinder/Piston Installation128
Camshaft/Cam Chain Tensioner130
Cam Chain Tensioner Removal131
Cam Chain Tensioner Inspection132
Cam Chain Tensioner Installation133
Camshaft Installation133
Cam Chain Tensioner Lifter135
Clutch: Contents, Service Information139
Clutch: Troubleshooting140
Front Crankcase Cover Removal141
Bearing Replacement141
Centrifugal Clutch/Primary Drive Gear Removal142
Centrifugal Clutch/Primary Drive Gear Inspection143
Centrifugal Clutch/Primary Drive Gear Assembly146
Centrifugal Clutch/Primary Drive Gear Installation148
Change Clutch Removal149
Change Clutch Inspection151
Change Clutch Installation153
Front Crankcase Cover Installation155
Gearshift Linkage: Contents, Service Information, Troubleshooting159
Gearshift Linkage Removal160
Gearshift Linkage Inspection, Installation162
Reverse Stopper Shaft Removal165
Alternator/Starter Clutch168
Alternator/Starter Clutch: Contents, Service Information, Troubleshooting169
Recoil Starter Removal, Disassembly170
Recoil Starter Assembly171
Recoil Starter Installation173
Alternator Removal174
Alternator Cover Disassembly174
Flywheel/Starter Clutch Removal176
Rear Crankcase Cover Removal176
Starter Clutch Inspection/Disassembly177
Starter Clutch Assembly178
Rear Crankcase Cover Installation179
Flywheel/Starter Clutch Installation180
Alternator Installation/Assembly181
Crankshaft/Balancer/Transmission Overview184
Crankshaft/Balancer/Transmission: Contents, Service Information185
Crankshaft/Balancer/Transmission: Troubleshooting187
Crankcase Separation188
Transmission Removal/Disassembly188
Crankcase Bearing Locations193
Reverse Idle Shaft194
Crankshaft/Balancer Removal196
Crankshaft/Balancer Inspection197
Crankshaft/Balancer Installation198
Crankcase Assembly199
Front Wheel/Suspension/Steering: Contents, Service Information203
Front Wheel/Suspension/Steering: Troubleshooting204
Handlebar Removal/Installation205
Throttle Housing Disassembly207
Throttle Housing Assembly208
Front Wheel Removal/Installation209
Tires Removal209
Tire Repair211
Tire Assembly212
Tie-Rod/Knuckle Removal213
Tie-Rod/Knuckle Inspection215
Knuckle Bearing Inspection/Replacement216
Knuckle Installation217
Tie-Rod Assembly, Installation218
Upper/Lower Arms Removal, Inspection220
Upper/Lower Arms Installation221
Steering Shaft Removal221
Steering Shaft Inspection222
Steering Shaft Installation224
Front Shock Absorber Removal, Disassembly, Inspection226
Front Shock Absorber Assembly227
Front Shock Absorber Installation228
Rear Wheel/Suspension: Overview230
Rear Wheel/Suspension: Contents, Service Information231
Rear Wheel/Suspension: Troubleshooting232
Rear Wheel Removal, Installation233
Rear Shock Absorber Removal233
Rear Shock Absorber Disassembly, Inspection234
Rear Shock Absorber Assembly235
Rear Shock Absorber Installation236
Swingarm Removal236
Swingarm Inspection238
Pivot Bearing Replacement238
Swingarm Installation239
Brake System Overview242
Brake System: Contents, Service Information243
Brake System: Troubleshooting244
Brake Fluid Replacement/Air Bleeding245
Brake Fluid Draining245
Brake Bleeding246
Brake Hose/Brake Pipe/Breather Tube Inspection246
Master Cylinder Disassembly247
Master Cylinder Inspection/Assembly248
Brake Shoes/Wheel Cylinder/Adjuster Disassembly249
Wheel Cylinder/Adjuster Inspection252
Front Brake Panel Inspection252
Front Brake Waterproof Seal Inspection/Replacement253
Front Brake Waterproof Seal Assembly254
Rear Brake Removal/Disassembly257
Rear Brake Assembly/Installation261
Brake Pedal Removal/Installation265
Front Driving Mechanism Overview268
Front Driving Mechanism: Contents, Service Information269
Front Driving Mechanism: Troubleshooting270
Front Drive Shaft Removal271
Front Drive Shaft Inspection/Disassembly272
Front Drive Shaft Assembly273
Front Drive Shaft Installation276
Front Differential Removal277
Backlash/Front Differential Inspection278
Differential Case Disassembly279
Gear Tooth Contact Pattern Check280
Differential Assembly Inspection282
Differential Disassembly283
Differential Inspection284
Drive Pinion Removal285
Drive Pinion Disassembly/Assembly286
Case Bearing Replacement287
Drive Pinion Installation288
Differential Assembly289
Differential Case Assembly/Installation292
Rear Driving Mechanism Overview296
Rear Driving Mechanism: Contents, Service Information297
Rear Driving Mechanism: Troubleshooting298
Rear Axle Removal299
Rear Axle Inspection300
Rear Final Drive302
Gear Case Removal/Inspection302
Backlash Inspection303
Gear Case Disassembly303
Gear Tooth Pattern Check304
Gear Case Assembly Overview311
Gear Case Installation312
Rear Axle Installation313
Rear Drive Shaft Removal/Inspection/Installation316
Battery/Charging System Overview318
Battery/Charging System: Contents, Service Information319
Battery/Charging System Troubleshooting321
Battery Removal/Installation322
Voltage Inspection322
Battery Testing322
Battery Charging323
Charging System325
Leakage/Regulated Voltage Inspection325
Alternator Charging Coil Inspection326
Regulator/Rectifier: Voltage Inspection326
Regulator/Rectifier Replacement327
Ignition System: Overview328
Ignition System: Contents, Service Information329
Ignition System Troubleshooting331
Ignition System Inspection332
Ignition Primary Peak Voltage332
Ignition Pulse Generator Peak Voltage333
Ac Sensor Line Inspection334
Ignition Coil Inspection334
Ignition Coil Removal/Installation335
Ignition Pulse Generator Inspection/Removal/Installation335
Ignition Timing336
Electric Starter Overview338
Electric Starter: Contents, Service Information339
Electric Starter: Troubleshooting340
Starter Motor Removal/Disassembly/Inspection341
Starter Motor Assembly343
Starter Motor Installation345
Starter Relay Switch: Operation Inspection345
Voltage/Continuity Inspection345
Diode Removal/Inspection/Installation346
Lights/Switches: Overview348
Lights/Switches: Contents, Service Information, Troubleshooting349
Headlight Bulb Replacement351
Headlight Bulb Removal/Installation352
Assist Headlight: Bulb Replacement352
Taillight Bulb Replacement/Removal/Installation353
Indicator Lamps Bulb Replacement354
Ignition Switch Inspection354
Handlebar Switches355
Neutral/Reverse Switch Inspection355
Neutral/Reverse Switch Removal/Installation356
Cooling Fan Control Unit: System Inspection356
Oil Thermo Sensor Inspection/Removal/Installation357
Wiring Diagram360
Technical Feature361
Power Train361
Limited Slip Differential362
Ohv Valve Train363
Gearshift Mechanism364
Troubleshooting365
Engine Does Not Start Or Is Hard To Start365
Engine Lacks Power366
Poor Performance At High Speeds368
Poor Handling368
Index369