Honda TRX400EX FOURTRAX 1999 Service Manual page 149

INSPECTION
Check the gear dogs and teeth for abnormal wear or
damage.
Measure the gear I.D.
SERVICE LIMITS: M 4 25.08 mm (0.987 in1
Measure the gear bushing O.D.
SERVICE LIMITS: M4, M5: 24.90 mm (0.980
27.94 mm (1.100
Calculate the gear-to-bushing clearance.
SERVICE LIMIT 0.10 mm (0.004 in)
Measure the gear bushing I.D.
SERVICE LIMITS: M 4 22.10 mm (0.870 in1
Check the mainshaft and countershaft for abnormal
wear or damage.
Measure the malnshaft O.D.
SERVICE LIMIT 21.92 mm (0.863 in)
Measure the countershaft
gears.
SERVICE LIMITS At C1: 19.94 mm (0.785 in)
At C2, C 3 24.92 mm (0.981 in1
Calculate the gear bushing-to-shaft clearance.
SERVICE LIMIT 0.10 mm 10.004 in)
SHIFT DRUM
Check the shift drum guide grooves for abnormal
wear or damage.
Check the shift drum journals for scoring, scratches
or evidence of insufficient lubrication.
at the M4 gear.
O.D. at the C1, C2 and C3
I
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