Honda TRX400FGA - Service Manual

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A few Words about Safety2
Service Information2
Important Safety Precautions2
Contents3
Symbols4
General Information5
Service Rules6
Model Identification6
Model Identification Label7
Frame Serial Number7
Engine Serial Number7
Carburetor Identification Number7
Colour Label8
General Specifications9
Lubrication System Specifications11
Fuel System Specifications11
Cylinder Head/Valve/Camshaft Specifications12
Cylinder/Piston Specifications12
Centrifugal Clutch Specifications12
Alternator/Starter Clutch Specifications13
Sub-Transmission Specifications13
Crankshaft/Automatic Transmission Specifications13
Front Wheel/Suspension/Steering Specifications14
Rear Wheel/Suspension Specifications14
Brake System Specifications14
Front Driving Mechanism Specifications15
Rear Driving Mechanism Specifications15
Battery/Charging System Specifications15
Ignition System Specifications15
Lights/Meters/Switches Specifications16
Standard Torque Values17
Engine & Frame Torque Values17
Lubrication & Seal Points23
Cable & Harness Routing28
Source of Emissions43
Exhaust Emission Control System43
Crankcase Emission Control System43
Noise Emission Control System43
Emission Control Information Label (U.S.A. Only)44
Technical Feature45
GPS Navigation Meter (GPS Type)46
Global Positioning System (GPS)46
Structure/Function47
Navigation System47
Compass47
Automatic Clock Adjustment47
Frame/Body Panels/Exhaust System49
Frame/Body Panels/Exhaust System Service Information50
Frame/Body Panels/Exhaust System Troubleshooting50
Body Panel Locations51
Seat/Side Cover Removal52
Tank Side Covers and Tank Top Cover52
Seat/Side Cover Installation53
Front Carrier/Bumper/Front Fender Removal54
Front Carrier/Bumper/Front Fender Disassembly55
Front Carrier/Bumper/Front Fender Installation56
Rear Luggage Carrier/Rear Fender Removal58
Center Mudguard59
Rear Luggage Carrier/Rear Fender Disassembly60
Rear Luggage Carrier/Rear Fender Installation61
Exhaust System Removal62
Exhaust Pipe62
Muffler62
Exhaust System Installation63
Maintenance65
Maintenance Service Information66
Maintenance Schedule68
Fuel Line69
Throttle Operation69
Carburetor Choke70
Air Cleaner70
Air Cleaner Housing Drain Hose72
Spark Plug72
Spark Plug Inspection73
Reusing a Spark Plug73
Replacing a Spark Plug73
Valve Clearance74
Engine Oil Level Check76
Engine Oil Change77
Engine Oil Filter78
Engine Idle Speed78
Drive Shaft Boots79
Rear Final Gear Case Oil and Differential Oil79
Brake Fluid81
Brake Shoes Wear82
Brake System82
Front Brake82
Rear Brake82
Skid Plate, Engine Guard84
Suspension84
Swingarm Bearings85
Spark Arrester Cleaning85
Nuts, Bolts, Fasteners86
Wheels/Tires86
Steering Shaft Holder Bearing86
Steering System87
Lubrication System89
Lubrication System Diagram90
Lubrication System Service Information91
Lubrication System Tools92
Lubrication System Troubleshooting94
Oil Pressure Check95
Front Crankcase Cover Removal96
Oil Pressure Relief Valve Inspection96
Relief Valve Inspection97
Oil Feed Pipe Inspection98
Bearing Replacement99
Oil Pump Removal102
Oil Pump Disassembly102
Oil Pump Inspection103
Oil Pump Assembly104
Oil Pump Installation106
Oil Cooler Removal107
Cooling Fan Removal108
Cooling Fan Disassembly109
Cooling Fan Assembly110
Cooling Fan Installation111
Oil Cooler Installation112
Fuel System115
Fuel System Components116
Fuel System Service Information117
Fuel System Troubleshooting118
Air Cleaner Housing Removal/Installation119
Sub-Air Cleaner Removal120
Sub-Air Cleaner Cleaning120
Carburetor Removal121
Sub-Air Cleaner Installation121
Carburetor Disassembly/Inspection122
Starting Enrichment (SE) Valve Inspection122
Hoses, Cable and Carburetor Heater123
Vacuum Chamber124
Float and Jets125
Primer Knob126
Air Cut-Off Valve127
Air Joint127
Carburetor Body Cleaning127
Carburetor Assembly128
Carburetor Installation134
Pilot Screw Adjustment137
Idle Drop Procedure137
High Altitude Adjustment138
Fuel Tank Removal139
Fuel Strainer Screen Cleaning141
Fuel Tank Installation142
Engine Removal/Installation145
Engine Removal/Installation System Components146
Engine Removal/Installation Service Information147
Engine Removal148
Engine Installation151
Gearshift Lever Free Play Adjustment156
Cylinder Head/Valve/Camshaft159
Cylinder Head/Valve/Camshaft System Components160
Cylinder Head/Valve/Camshaft Service Information161
Cylinder Head/Valve/Camshaft Tools162
Cylinder Head/Valve/Camshaft Troubleshooting163
Cylinder Compression164
Cylinder Head Cover Removal/Disassembly164
Cylinder Head Removal166
Rocker Arm/Shaft Inspection166
Cylinder Head Disassembly167
Cylinder Head Inspection168
Valve/Valve Guide169
Valve Guide Replacement170
Valve Seat Inspection/Refacing171
Camshaft Removal173
Camshaft Inspection175
Cam Follower176
Cam Chain Tensioner176
Camshaft Installation177
Cylinder Head Assembly179
Cylinder Head Installation180
Cylinder Head Cover Assembly/Installation182
Cylinder/Piston185
Cylinder/Piston System Components186
Cylinder/Piston Service Information187
Cylinder/Piston Troubleshooting187
Cylinder/Piston Removal188
Piston Disassembly188
Cylinder Inspection189
Piston/Piston Ring190
Cylinder Stud Bolt Replacement191
Cylinder/Piston Installation192
Piston Assembly192
Centrifugal Clutch195
Centrifugal Clutch Component Location196
Centrifugal Clutch Service Information197
Centrifugal Clutch Troubleshooting198
Centrifugal Clutch Removal199
Centrifugal Clutch Inspection200
One-Way Clutch200
Clutch Drum200
Weight Lining/Weight Spring/Clutch Spring201
Alternator/Starter Clutch207
Alternator/Starter Clutch System Components208
Alternator/Starter Clutch Service Information209
Alternator/Starter Clutch Troubleshooting209
Recoil Starter Removal210
Recoil Starter Disassembly210
Recoil Starter Assembly212
Alternator Stator215
Recoil Starter Installation215
Alternator Cover Removal215
Alternator Cover Installation216
Stator and Ignition Pulse Generator Removal/Installation216
Flywheel/Starter Clutch Removal218
Starter Clutch Disassembly/Inspection219
Starter Clutch Assembly220
Starter Clutch Installation221
Sub-Transmission/Gearshift Linkage223
Sub-Transmission/Gearshift Linkage System Components224
Sub-Transmission/Gearshift Linkage Service Information225
Sub-Transmission/Gearshift Linkage Tools226
Sub-Transmission/Gearshift Linkage Troubleshooting227
Rear Crankcase Cover Removal228
Rear Crankcase Cover Installation231
Sub-Transmission/Gearshift Linkage Disassembly234
Sub-Transmission/Gearshift Linkage Assembly237
Crankshaft/Automatic Transmission239
Crankshaft/Automatic Transmission System Components240
Crankshaft/Automatic Transmission Service Information241
Crankshaft/Automatic Transmission Tools241
Crankshaft/Automatic Transmission Troubleshooting243
Crankcase Separation245
Oil Strainer Cleaning247
Breather Separator Replacement247
Automatic Transmission Removal248
Automatic Transmission Inspection248
Automatic Transmission Installation249
Crankshaft/Balancer Removal249
Crankshaft/Balancer Inspection250
Crankshaft and Balancer Installation251
Crankcase Bearing Replacement252
Rear Crankcase252
Front Crankcase253
Crankcase Assembly254
Front Wheel/Suspension/Steering257
Front Wheel/Suspension/Steering System Components258
Front Wheel/Suspension/Steering Service Information259
Front Wheel/Suspension/Steering Tools260
Front Wheel/Suspension/Steering Troubleshooting261
Handlebar Removal262
Handlebar Installation264
Throttle Housing Disassembly266
Throttle Housing Assembly267
Front Wheel Removal/Installation268
Tires Removal268
Tire Repair269
Tire Assembly271
Wheel Hub/Knuckle Removal271
Wheel Hub/Knuckle Inspection273
Ball Joint Replacement275
Ball Joint Installation276
Front Shock Absorber Removal278
Front Shock Absorber Inspection278
Front Shock Absorber Installation278
Suspension Arm Removal279
Suspension Arm Inspection280
Suspension Arm Installation281
Steering Shaft Removal282
Steering Shaft Inspection283
Steering Shaft Installation285
Tie-Rod Removal287
Tie-Rod Inspection287
Tie-Rod Disassembly/Assembly288
Tie-Rod Installation288
Rear Wheel/Suspension289
Rear Wheel/Suspension System Components290
Rear Wheel/Suspension Service Information291
Rear Wheel/Suspension Tools292
Rear Wheel/Suspension Troubleshooting293
Rear Wheel Removal/Installation294
Rear Shock Absorber Removal294
Rear Shock Absorber Inspection295
Pivot Bearing Replacement295
Swingarm Removal296
Rear Shock Absorber Installation296
Swingarm Inspection298
Swingarm Pivot Bearing Replacement299
Swingarm Installation300
Brake System Component Location304
Brake System Service Information305
Brake System Tools306
Brake System Troubleshooting306
Brake Fluid Replacement/Air Bleeding307
Brake Fluid Draining307
Brake Fluid Filling307
Brake Bleeding308
Brake Hose/Brake Pipe/Breather Hose Inspection309
Front Master Cylinder Removal309
Front Master Cylinder Disassembly310
Front Master Cylinder Inspection311
Front Master Cylinder Assembly311
Front Brake Shoes/Drum314
Brake Drum Removal314
Brake Shoe Replacement315
Water Seal Inspection316
Water Seal Replacement316
Front Brake Panel Inspection317
Brake Drum Installation317
Front Wheel Cylinder/Brake Panel Disassembly318
Front Wheel Cylinder/Brake Panel Inspection320
Front Wheel Cylinder/Brake Panel Assembly320
Rear Brake Inspection323
Dust Seal Replacement324
Brake Panel Disassembly325
Brake Panel Bearing Replacement326
Brake Panel Assembly328
Brake Pedal Removal331
Brake Pedal Installation332
Front Driving Mechanism333
Front Driving Mechanism System Components334
Front Driving Mechanism Service Information335
Front Driving Mechanism Tools336
Front Driving Mechanism Troubleshooting338
Front Drive Shaft Removal339
Front Drive Shaft Disassembly/Inspection340
Front Drive Shaft Assembly342
Front Drive Shaft Installation344
Differential Removal346
Differential Disassembly/Inspection348
Propeller Shaft Inspection348
Operation Check349
Backlash Inspection349
Differential Case Disassembly350
Gear Tooth Contact Pattern Check351
Differential Inspection352
Differential Disassembly353
Differential Components Inspection354
Ring Gear354
Differential Housing/Face Cam/Cam Followers354
Pinion Gear Removal355
Side Cone Spring355
Case Bearing Replacement356
Differential Bearing356
Pinion Needle Bearing357
Differential Assembly358
Pinion Gear Installation359
Differential Case Assembly361
Propeller Shaft Assembly362
Differential Installation363
Rear Driving Mechanism367
Rear Driving Mechanism System Components368
Rear Driving Mechanism Service Information369
Rear Driving Mechanism Tools370
Rear Driving Mechanism Troubleshooting372
Rear Axle Removal373
Rear Axle Inspection374
Final Drive Removal375
Final Drive Inspection376
Final Drive Disassembly/Inspection377
Final Gear Case Disassembly378
Pinion Gear Bearing/Shim Replacement381
Final Gear Case Bearing Replacement382
Ring Gear Bearing382
Final Drive Assembly384
Ring Gear Clearance Inspection385
Final Gear Case Assembly386
Final Drive Installation387
Rear Axle Installation388
Battery/Charging System391
Battery/Charging System Component Location392
Battery/Charging System System Diagram392
Battery/Charging System Service Information393
Battery/Charging System Troubleshooting394
Battery Removal/Installation395
Battery Voltage Inspection395
Battery Testing395
Battery Charging396
Charging System Inspection398
Current Leakage Inspection398
Charging Voltage Inspection398
Alternator Charging Coil Inspection399
Regulator/Rectifier399
Wire Harness Inspection399
Regulator/Rectifier Removal/Installation400
Ignition System401
Ignition System Component Location402
Ignition System System Diagram402
Ignition System Service Information403
Ignition System Troubleshooting404
Ignition System Inspection405
Ignition Coil Primary Peak Voltage405
Ignition Pulse Generator Peak Voltage406
Ignition Coil Removal/Installation407
Ignition Timing408
Electric Starter409
Electric Starter Component Location410
Electric Starter System Diagram410
Electric Starter Service Information411
Electric Starter Troubleshooting412
Starter Motor Removal414
Starter Motor Disassembly/Inspection414
Starter Motor Assembly417
Starter Motor Installation419
Starter Relay Switch Operation Inspection420
Starter Relay Switch Circuit Inspection420
Starter Relay Switch Function Inspection420
Diode Inspection421
Lights/Meters/Switches423
Lights/Meters/Switches Component Location424
Lights/Meters/Switches Service Information425
Headlight Bulb Replacement426
Headlight Removal/Installation427
Tail/Brake Light Bulb Replacement427
Tail/Brake Light Removal/Installation428
Accessory Socket Inspection428
Accessory Socket Replacement429
Ignition Switch Inspection429
Ignition Switch Removal/Installation429
Handlebar Switch Inspection430
Carburetor Heater/Air Temperature Switch System Inspection431
Carburetor Heater Inspection431
Air Temperature Switch Inspection432
Combination Meter/Rear Vehicle Speed Sensor (VSS)433
Power/Ground Line Inspection433
Speedometer/Rear VSS433
Combination Meter Removal/Installation434
Oil Temperature Sensor/Cooling Fan435
Oil Temperature Indicator System Inspection435
Oil Temperature Indicator Does Not Come On, When the Oil Is over the Specified Temperature436
Cooling Fan System Inspection437
Cooling Fan Motor Does Not Start, When the Oil Is over the Specified Temperature437
Cooling Fan Does Not Stop438
Oil Temperature Sensor Inspection439
GPS Receiver Inspection440
GPS Indicator Blinks (Communication Error)441
Brake Light Switch443
Front Brake Lever443
Rear Brake Lever443
Rear Brake Pedal443
Front Brake Switch444
Selectable 4WD System445
Selectable 4WD System Component Location446
Selectable 4WD System System Diagram446
Selectable 4WD System Service Information447
Selectable 4WD System Troubleshooting Chart447
Selectable 4WD System Troubleshooting447
Problem Code 2: Front Vehicle Speed Sensor (VSS)448
Problem Code 3: Rear Vehicle Speed Sensor (VSS)450
Problem Code 4: System Voltage452
Problem Code 5: Front Final Clutch System452
Rear Vehicle Speed Sensor (VSS) Removal454
Rear Vehicle Speed Sensor (VSS) Installation454
Hondamatic457
Hondamatic Component Location458
Hondamatic Service Information459
Hondamatic Connector Location460
Hondamatic Circuit Diagram461
Before Starting Troubleshooting462
Self-Diagnostic Function462
Retrieval/Erasure of Problem Code463
Problem Code Blink Duration464
To Erase the Problem Code464
Erasure Confirmation Blink Duration464
Initial Setting Procedure465
Troubleshooting Chart468
Diagnostic Troubleshooting469
Problem Code 1: Ignition Pulse Generator System469
Problem Code 2: Vehicle Speed Sensor (VSS) System471
Problem Code 3: Gear Position Switch System473
Problem Code 4: Throttle Position (TP) Sensor System474
Problem Code 5: Angle Sensor System (Motor Lock)476
Problem Code 6: Angle Sensor System (Automatic Transmission Swash Plate Angle)481
Problem Code 7: ESP Shift Switch System484
Problem Code 8: ECM EEPROM (Writing/Readout Circuit)485
Problem Code 9: Mode Select Switch System (Auto and ESP)486
Problem Code 10, 11, 13: ECM Voltage Converter Circuit, ECM Fail-Safe Relay Circuit, ECM CPU487
Problem Code 12: ECM Motor Driver Circuit488
Problem Indicated (Mode 1), but no Code Is Retrievable490
Problem Not Detected by ECM491
Drive/Neutral/Reverse Switch Inspection494
Drive/Neutral/Reverse Switch Replacement494
ESP Shift Switch Inspection495
Mode Select Switch Inspection496
Mode Select Switch Replacement496
Throttle Position (TP) Sensor Inspection497
Throttle Position (TP) Sensor Replacement498
Angle Sensor Inspection498
Angle Sensor Replacement499
Sensor Resistance499
Control Motor Removal/Installation500
Sensor Preload500
Engine Control Module (ECM) Removal/Installation502
Wiring Diagrams503
Standard Type504
GPS Type505
Troubleshooting506
Engine Does Not Start or Is Hard to Start507
Engine Lacks Power508
Poor Performance at Low and Idle Speed510
Poor Performance at High Speed511
Poor Handling511
Index512

Brand	Honda
Model	TRX400FGA
Category	Offroad Vehicle
Language	English

Honda TRX400FGA - Service Manual

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