Honda TRX400FGA 2004 Manuals

Manuals and User Guides for Honda TRX400FGA 2004. We have 1 Honda TRX400FGA 2004 manual available for free PDF download: Service Manual

Honda TRX400FGA 2004 Service Manual

Honda TRX400FGA 2004 Service Manual (514 pages)

Brand: Honda | Category: Offroad Vehicle | Size: 53.34 MB

Table of Contents

A few Words about Safety
2
Service Information
2
Important Safety Precautions
2
Contents
3
Symbols
4
Table of Contents
5
General Information
5
Service Rules
6
Model Identification
6
General Specifications
9
Lubrication System Specifications
11
Fuel System Specifications
11
CYLINDER HEADIVALVE/ CAMSHAFT Specifications
12
Cylinder/Piston Specifications
12
Centrifugal Clutch Specifications
12
Alternator/Starter Clutch Specifications
13
SUB-TRANSMISSION Specifications
13
Crankshaft/Automatic Transmission Specifications
13
Brake System Specifications
14
FRONT DRIVING MECHANISM Specifications
15
Ignition System Specifications
15
Electric Starter Specifications
15
Lights/Meters/Switches Specifications
16
Standard Torque Values
17
Engine & Frame Torque Values
17
Lubrication & Seal Points
23
Cable & Harness Routing
28
Emission Control Systems
43
Emission Control Information Label
44
LABEL (U.S.A. Only)
44
- Technical Feature
  45
- General Description
  46
- Global Positioning System (GPS)
  46
- Gps Navigation Meter
  46
- Automatic Clock Adjustment
  47
- Compass
  47
- Structure/Function
  47
- Frame/Body Panels/Exhaust System
  49
- Service Information
  50
- Torque Values
  50
- Troubleshooting
  50
- Body Panel Locations
  51
- Seat/Side Cover
  52
  - Tank Side Covers and Tank Top Cover
    52
  - Front Bumper
    54
  - Front Fender
    54
  - Front Luggage Carrier
    54
  - Rear Luggage Carrier
    58
  - Center Mudguard
    59
- Rear Fender
  59
  - Toolbox
    60
  - Exhaust Pipe
    62
- Exhaust System
  62
  - Muffler
    62
  - Maintenance
    65
- Service Information
  66
- Maintenance Schedule
  68
- Fuel Line
  69
- Throttle Operation
  69
- Air Cleaner
  70
- Carburetor Choke
  70
- Air Cleaner Housing Drain Hose
  72
- Spark Plug
  72
  - Replacing a Spark Plug
    73
  - Reusing a Spark Plug
    73
- Valve Clearance
  74
- Engine Oil
  76
  - Level Check
    76
  - Oil Change
    77
- Engine Idle Speed
  78
- Engine Oil Filter
  78
- Drive Shaft Boots
  79
- Rear Final Gear Case Oil and Differential Oil
  79
- Differential Oil
  80
- Brake Fluid
  81
- Front Brake
  81
- Brake Shoes Wear
  82
- Brake System
  82
- Rear Brake
  82
- Skid Plate, Engine Guard
  84
- Suspension
  84
- Spark Arrester
  85
- Swingarm Bearings
  85
- Nuts, Bolts, Fasteners
  86
- Steering Shaft Holder Bearing
  86
- Wheels/Tires
  86
- Steering System
  87
- Lubrication System
  89
- Lubrication System Diagram
  90
- Front Crankcase Cover
  96
  - Oil Pressure Relief Valve Inspection
    96
  - Relief Valve Inspection
    97
  - Oil FEED PIPE INSPECTION
    98
  - Bearing Replacement
    99
- OIL Pump
  102
  - Oil Cooler Removal
    107
  - Cooling Fan Removal
    108
  - Cooling Fan Oisassembly
    109
  - Cooling Fan Assembly
    110
  - Cooling Fan Installation
    111
  - Oil Cooler Installation
    112
  - Fuel System
    115
  - Fuel System System Components
    116
  - Fuel System Service Information
    117
  - Fuel System Tool
    117
  - Fuel System Torque Values
    117
  - Engine Cranks but Won't Start
    118
  - Engine Stalls, Hard to Start, Rough Idling
    118
  - Fuel System Troubleshooting
    118
  - Lean Mixture
    118
  - Air Cleaner Housing Removal/Installation
    119
  - Sub-Air Cleaner Cleaning
    120
  - Sub-Air Cleaner Removal
    120
- Carburetor Removal
  121
  - Sub-Air Cleaner Installation
    121
  - Carburetor Disassembly/Inspection
    122
  - Starting Enrichment (Se) Valve
    122
  - Hoses, Cable and Carburetor Heater
    123
  - Vacuum Chamber
    124
  - Float and Jets
    125
  - Primer Knob
    126
  - Air Cut-Off Valve
    127
  - Air Joint
    127
  - Carburetor Body Cleaning
    127
- Carburetor Assembly
  128
- Float Level
  131
- Carburetor Installation
  134
- Idle Drop Procedure
  137
- Pilot Screw Adjustment
  137
- High Altitude Adjustment
  138
  - High Altitude Pilot Screw Opening
    138
  - Idle Speed
    138
  - Standard Main Jet
    138
- Fuel Tank
  139
  - Fuel Strainer Screen Cleaning
    141
  - Fuel System Installation
    142
  - Engine Removal/Installation
    145
  - Engine Removal/Installation Components
    146
  - Engine Removal/Installation Service Information
    147
  - Engine Removal/Installation Specifications
    147
  - Engine Removal/Installation Torque Values
    147
  - Engine Removal
    148
  - Engine Installation
    151
  - Gearshift Lever Free Play Adjustment
    156
  - Cylinder Head/Valve/Camshaft
    159
  - Cylinder Head/Valve/Camshaft System Components
    160
  - Cylinder Head/Valve/Camshaft Service Information
    161
  - Cylinder Head/Valve/Camshaft Torque Values
    161
  - Cylinder Head/Valve/Camshaft Tools
    162
  - Compression too High
    163
  - Compression too Low
    163
  - Cylinder Head/Valve/Camshaft Troubleshooting
    163
  - Excessive Smoke
    163
- Cylinder Compression
  164
- Cylinder Head Cover Removal/Disassembly
  164
- Cylinder Head Removal
  166
- Rocker Arm/Shaft
  166
- Cylinder Head Disassembly
  167
  - Cylinder Head
    168
  - Valve Spring
    168
  - Valve/Valve Guide
    169
- Valve Guide Replacement
  170
- Valve Seat Inspection/Refacing
  171
- Camshaft Removal
  173
  - Push Rod
    175
  - Cam Chain Tensioner
    176
  - Cam Follower
    176
- Camshaft Installation
  177
- Cylinder Head Assembly
  179
- Cylinder Head Installation
  180
  - Cylinder Head Cover Assembly/Installation
    182
  - Cylinder/Piston
    185
- System Components
  186
  - Cylinder/Piston Service Information
    187
  - Cylinder/Piston Specifications
    187
  - Cylinder/Piston Torque Value
    187
  - Cylinder/Piston Troubleshooting
    187
- Cylinder/Piston Removal
  188
  - Piston Disassembly
    188
  - Cylinder Inspection
    189
  - Piston/Piston Ring
    190
  - Connecting Rod
    191
  - Cylinder Stud Bolt Replacement
    191
- Cylinder/Piston Installation
  192
  - Centrifugal Clutch
    195
  - Centrifugal Clutch Component Location
    196
  - Centrifugal Clutch Service Information
    197
  - Centrifugal Clutch Specifications
    197
  - Centrifugal Clutch Tools
    197
  - Centrifugal Clutch Torque Values
    197
  - Centrifugal Clutch Troubleshooting
    198
  - Clutch Operation Feels Rough
    198
  - Clutch Slips When Accelerating
    198
  - Clutch will Not Disengage
    198
  - Centrifugal Clutch Removal
    199
  - Centrifugal Clutch Inspection
    200
  - Clutch Drum
    200
  - One-Way Clutch
    200
  - Weight Lining/Weight Spring/Clutch Spring
    201
  - Crankshaft
    202
  - Alternator/Starter Clutch
    207
  - Alternator/Starter Clutch System Components
    208
  - Alternator/Starter Clutch Service Information
    209
  - Alternator/Starter Clutch Specifications
    209
  - Alternator/Starter Clutch Torque Values
    209
  - Alternator/Starter Clutch Troubleshooting
    209
- Recoil Starter
  209
  - Recoil Starter Disassembly
    210
  - Recoil Starter Removal
    210
  - Recoil Starter Assembly
    212
  - Alternator Cover Removal
    215
- Alternator Stator
  215
- Troubleshooting
  223
- System Components
  224
  - Sub-Transmission/Gearshift Linkage Troubleshooting
    227
  - Rear Crankcase Cover Removal
    228
- Sub-Transmission/Gearshift
  229
  - Sub-Transmission/Gearshift Linkage
    234
  - Output Shaft
    236
  - Reverse Idle Gear
    236
  - Shift Fork and Shaft
    236
  - Crankshaft/Automatic Transmission
    239
- Troubleshooting
  239
- Automatic Transmissio
  242
  - Crankshaft/Automatic Transmission Troubleshooting
    243
  - Oil Level Inspection
    243
  - Oil Pressure Test
    243
  - Crankcase Separation
    245
  - Breather Separator Replacement
    247
  - Oil Strainer Cleaning
    247
  - Automatic Transmission
    248
  - Crankshaft/Balancer
    249
  - Crankshaft and Balancer Installation
    251
- Crankcase Bearing Replacement
  252
  - Rear Crankcase
    252
  - Front Crankcase
    253
- Crankcase Assembly
  254
  - Front Wheel/Suspension/Steering
    257
  - Front Wheel/Suspension/Steering Components
    258
- System Components
  258
- Throttle Housing
  266
- Front Wheel
  268
- Tires
  268
- Tire Repair
  269
- Wheel Hub/Knuckle
  271
- Ball JOINT REPLACEMENT
  275
- Front Shock Absorber
  278
- Suspension Arm
  279
- Steering Shaft
  282
- Tie-Rod
  287
  - Rear Wheel/Suspension
    289
  - Rear Wheel/Suspension Components
    290
- System Components
  290
  - Rear Wheel/Suspension Service Information
    291
  - Rear Wheel/Suspension Specifications
    291
  - Rear Wheel/Suspension Torque Values
    291
  - Rear Wheel/Suspension Tools
    292
  - Rear Wheel Wobbling
    293
  - Rear Wheel/Suspension Troubleshooting
    293
  - Soft Suspension
    293
  - Steers to One Side or Does Not Track Straight
    293
- Rear Shock Absorber
  294
- Rear Wheel
  294
  - Pivot Bearing Replacement
    295
  - Swingarm Removal
    296
  - Brake System Service Information
    305
  - Brake System Specifications
    305
  - Brake System Torque Values
    305
  - Brake System Tools
    306
  - Brake System Troubleshooting
    306
  - Front Brake Lever Hard
    306
  - Poor Brake Performance
    306
  - Brake Fluid Draining
    307
  - Brake Fluid Filling
    307
  - Brake Fluid Replacement/Air Bleeding
    307
  - Brake Bleeding
    308
  - Brake Hose/Brake Pipe/Breather Hose Inspection
    309
  - Front Master Cylinder
    309
  - Brake Drum Removal
    314
  - Front Brake Shoes/Drum
    314
  - Brake Shoe Replacement
    315
  - Water Seal Inspection
    316
  - Water Seal Replacement
    316
  - Brake Drum Installation
    317
  - Front Brake Panel Inspection
    317
  - Front Wheel Cylinder/Brake Panel
    318
  - Brake Panel Assembly
    328
  - Front Driving Mechanism
    333
  - Front Driving Mechanism System Components
    334
  - Front Driving Mechanism Service Information
    335
  - Front Driving Mechanism Specifications
    335
  - Front Driving Mechanism Torque Values
    335
  - Front Driving Mechanism Tools
    336
  - Abnormal Noises When Turning
    338
  - Consistent Noise During Cruising
    338
  - Front Driving Mechanism Troubleshooting
    338
  - Gear Noises While Running
    338
- Front Drive Shaft
  339
- Differential Removal
  346
  - Differential Disassembly Inspection
    348
  - Propeller Shaft Inspection
    348
  - Backlash Inspection
    349
  - Operation Check
    349
  - Differential Case Disassembly
    350
  - Bearing Inspection
    351
  - Gear Tooth Contact Pattern Check
    351
  - Differential Inspection
    352
  - Differential Disassembly
    353
  - Differential Components Inspection
    354
  - Differential Housing/Face Cam/Cam Followers
    354
  - Ring Gear
    354
  - Pinion Gear Removal
    355
  - Side Cone Spring
    355
- Case Bearing Replacement
  356
  - Differential Bearing
    356
  - Pinion Needle Bearing
    357
- Differential Assembly
  358
  - Pinion Gear Installation
    359
  - Differential Case Assembly
    361
  - Propeller Shaft Assembly
    362
- Differential Installation
  363
- Rear Driving Mechanism
  367
- System Components
  368
  - Rear Driving Mechanism Service Information
    369
  - Rear Driving Mechanism Specifications
    369
  - Rear Driving Mechanism Torque Values
    369
  - Rear Driving Mechanism Tools
    370
  - Excessive Noise
    372
  - Oil Leak
    372
  - Rear Driving Mechanism Troubleshooting
    372
  - Wobble or Vibration in Vehicle
    372
- Rear Axle Removal
  373
- Final Drive Removal
  375
  - Final Drive Disassembly/Inspection
    377
  - Final Gear Case Disassembly
    378
  - Final Gear Case Bearing Replacement
    382
  - Ring Gear Bearing
    382
- Final Drive Assembly
  384
  - Ring Gear Clearance Inspection
    385
  - Final Gear Case Assembly
    386
- Final Drive Installation
  387
- Rear Axle Installation
  388
  - Battery/Charging System
    391
  - Battery/Charging System Component Location
    392
  - Battery/Charging System Diagram
    392
  - Battery Testing
    393
  - Battery/Charging System Service Information
    393
  - Battery/Charging System Specifications
    393
  - Battery Is Damaged or Weak
    394
  - Battery/Charging System Troubleshooting
    394
  - Battery Removal/Installation
    395
  - Battery Voltage Inspection
    395
  - Battery Charging
    396
  - Charging System Inspection
    398
  - Charging Voltage Inspection
    398
  - Current Leakage Inspection
    398
  - Alternator Charging Coil
    399
  - Regulator/Rectifier
    399
  - Wire Harness Inspection
    399
  - Battery Line
    400
  - Charging Coil Line
    400
  - Ground Line
    400
  - Ignition System
    401
- Component Location
  402
  - Ignition System Service Information
    403
  - Ignition System Specification
    403
  - Ignition System Tools
    403
  - Ignition System Torque Values
    403
  - Ignition System Troubleshooting
    404
  - No Spark at Spark Plug
    404
  - Ignition Coil Primary Peak Voltage
    405
- Ignition System Inspection
  405
  - Ignition Pulse Generator Peak Voltage
    406
  - Ignition Coil Removal/Installation
    407
  - Ignition Timing
    408
  - Electric Starter
    409
  - Electric Starter Component Location
    410
  - Electric Starter System Diagram
    410
  - Electric Starter Service Information
    411
  - Electric Starter Specifications
    411
  - Electric Starter Troubleshooting
    412
  - Starter Motor Does Not Turn
    412
  - Starter Motor Turns Engine Slowly
    413
  - Starter Motor Turns, but Engine Does Not Turn
    413
  - Starter Relay Switch Inspection
    413
  - Starter Motor
    414
  - Starter Motor Assembly
    417
  - Circuit Inspection
    420
  - Operation Inspection
    420
  - Starter Relay Switch
    420
  - Diode
    421
  - Lights/Meters/Switches
    423
  - Lights/Meters/Switches Component Location
    424
  - Lights/Meters/Switches Service Information
    425
  - Lights/Meters/Switches Specifications
    425
  - Lights/Meters/Switches Tool
    425
  - Lights/Meters/Switches Torque Values
    425
  - Headlight Bulb Replacement
    426
  - Bulb Replacement
    427
- Tail/Brake Light
  427
- Accessory Socket
  428
- Ignition Switch
  429
- Socket
  429
- Handlebar Switch
  430
  - Carburetor Heater Air Temperature Switch
    431
  - Carburetor Heater Inspection
    431
  - Air Temperature Switch Inspection
    432
  - Combination Meter Rear Vehicle Speed Sensor (Vss)
    433
  - Power Input Line
    433
  - Power/Ground Line Inspection
    433
  - Speedometer/Rear Vss
    433
  - Combination Meter Removal/Installation
    434
  - Oil Temperature Indicator System Inspection
    435
  - Oil Temperature Sensor Cooling Fan
    435
  - Cooling Fan System Inspection
    437
  - Cooling Fan Does Not Stop
    438
  - Oil TEMPERATURE SENSOR INSPECTION
    439
- Gps Receiver
  440
  - GPS Indicator Blinks
    441
  - GPS Receiver Connector Check
    441
  - GPS Receiver Ground Line Inspection
    441
  - GPS Receiver Input Voltage Inspection
    441
  - GPS Receiver Backup Voltage Inspection
    442
  - Gps Receiver Replacement
    442
  - Gps Start·up Time Is Taking too Long
    442
  - GPS System Reset
    442
- Brake Light Switch
  443
- Rear Brake Pedal
  443
- Front Brake Switch
  444
- Rear Brake Lever
  443
- Front Brake Lever
  443
- Selectable 4Wd System
  445
- Selectable 4Wd System Component Location
  446
- Selectable 4Wd System System Diagram
  446
- Selectable 4Wd System Service Information
  447
- Selectable 4Wd System Troubleshooting
  447
- Selectable 4Wd System Self-Diagnostic Function
  447
- Front VSS Connector Inspection
  448
- Front VSS Input Line Inspection
  448
- Front VSS Line Inspection
  448
- Front VSS Line Short Circuit Inspection
  449
- Front VSS Mechanical Inspection
  449
- Failure Reproduction
  449
- Rear VSS Line Inspection
  450
- Rear VSS Input Line Inspection
  450
- Rear VSS Connector Inspection
  450
- Rear VSS Line Short Circuit Inspection
  451
- Rear VSS Mechanical Inspection
  451
- System Voltage
  452
- Front Final Clutch System
  452
- ECM Power Input Line Inspection
  452
- Front Final Clutch Line Open Circuit Inspection
  453
- Front Final Clutch Line Short Circuit Inspection
  453
- Front Final Clutch Inspection
  453
- Rear Vehicle Speed Sensor (Vss)
  454
- Hondamatic
  457
- Hondamatic Component Location
  458
- Hondamatic Tool
  459
- Hondamatic Torque Values
  459
- Hondamatic Service Information
  459
- Hondamatic Connector Location
  460
- Hondamatic Circuit Diagram
  461
- Before Starting Troubleshooting
  462
- Retrieval/Erasure of Problem Code
  463
- Problem Code Blink Duration
  464
- To Erase the Problem Code
  464
- Erasure Confirmation Blink Duration
  464
- Initial Setiing Procedure
  465
- Hondamatic Troubleshooting Chart
  468
- Ignition Pulse Generator System
  469
- Ignition Pulse Generator Peak Voltage Inspection
  470
- System Failure Reproduction
  470
- Ignition Pulse Generator Line Inspection
  470
- Ground Cable Connection Inspection
  470
- Vehicle Speed Sensor System
  471
- VSS Line Inspection
  472
- Rear VSS Installation Condition
  472
- Wire Harness Continuity Inspection
  472
- Gear Position Switch System
  473
- Gear Position Switch Connection Inspection
  473
- Gear Position Switch Line Inspection
  473
- Throttle Position (TP) Sensor System
  474
- TP Sensor Resistance
  474
- TP Sensor Installation Condition
  475
- TP Sensor Input Voltage Inspection
  475
- TP Sensor Line Inspection
  475
- Angle Sensor Connection Inspection
  476
- Angle Sensor System (Motor Lock)
  476
- ESP Shift Switch Operation Inspection
  477
- Control Motor Power Input Line Inspection
  477
- Initial Setting Procedure
  477
- Control Motor Ground Line Inspection
  478
- Control Motor Line Inspection
  478
- Control Motor Circuit Inspection
  478
- Control Motor Inspection
  479
- Automatic Transmission Operation Inspection
  479
- Angle Sensor Resistance Inspection
  480
- Angle Sensor Line Inspection
  480
- Angle Sensor System
  481
- Ecm Eeprom
  485
- ESP Shift Switch Inspection
  485
- Mode Select Switch Line Inspection
  486
- Mode Select Switch System (Auto and ESP)
  486
- Mode Select Switch Connection Inspection
  486
- ECM Voltage Converter Circuit, ECM Fail-Safe Relay Circuit, ECM CPU
  487
- Mode Select Switch Inspection
  487
- ECM Motor Driver Circuit
  488
- Ecm/Control Motor Connection Inspection
  488
- But no Code Is Retrievable
  490
- Problem Not Detected by Ecm
  491
- Meter Connection Inspection
  491
- Drive/Neutral/Reverse Switch
  494
- ESP Shift Switch
  495
- Mode Select Switch
  496
- Throttle Position (Tp) Sensor
  497
- Input Voltage
  497
- Sensor Input Voltage
  498
- Angle Sensor
  498
- Sensor Resistance
  499
- Control Motor
  500
- Sensor Preload
  500
- Engine Control Module (Ecm)
  502
- Wiring Diagrams
  503
- Engine Does Not Start or Is Hard to Start
  507
- Engine Lacks Power
  508
- Poor Performance at Low and Idle Speed
  510
- Poor Performance at High Speed
  511
- Poor Handling
  511
- Steering Is Heavy
  511
- Any Wheel Is Wobbling
  511
- Index
  512

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