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Honda TRX400FW Service Manual

Honda TRX400FW
370 pages
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Table of Contents

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Honda TRX400FW Specifications

General IconGeneral
BrandHonda
ModelTRX400FW
CategoryOffroad Vehicle
LanguageEnglish

Summary

Symbols

General Information

Service Rules

Guidelines for proper vehicle servicing.

Model Identification

Visual guide to identifying the vehicle model.

Specifications

Technical specifications for various vehicle components.

Lubrication System

Details on the vehicle's lubrication system and oil.

Fuel System

Information related to the vehicle's fuel system.

Torque Values

Important torque specifications for various components.

Tools

List of specialized tools required for service.

Wiring Diagram

Electrical wiring diagram of the vehicle.

Frame/Body Panels/Exhaust System

Body Panel Locations

Diagram showing the location of all body panels.

Front Carrier/Bumper/Front Fender

Removal and installation of front carrier, bumper, and fender.

Rear Carrier/Rear Fender

Removal and installation of rear carrier and fender components.

Exhaust System

Removal and installation of the exhaust system.

Maintenance

Maintenance Schedule

Recommended maintenance intervals and tasks.

Spark Plug

Inspection, cleaning, and replacement of spark plugs.

Valve Clearance

Checking and adjusting valve clearance.

Engine Oil & Oil Filter

Procedures for checking and changing engine oil and filter.

Final Gear Case Oil and Differential Oil

Checking and changing final gear case and differential oil.

Lubrication System

Specifications

Technical specifications for the lubrication system.

Torque Values

Torque specifications for lubrication system components.

Troubleshooting

Common problems and solutions for the lubrication system.

Oil Cooler

Removal, inspection, and installation of the oil cooler.

Oil Pump

Removal, disassembly, inspection, and assembly of the oil pump.

Fuel System

Specifications

Specifications for fuel system components.

Torque Values

Torque specifications for fuel system parts.

Troubleshooting

Troubleshooting common fuel system issues.

Carburetor Removal

Procedures for removing the carburetor.

Carburetor Assembly

Assembly of the carburetor components.

Pilot Screw Adjustment

Adjusting the pilot screw for optimal performance.

Engine Removal/Installation

Specifications

Specifications related to engine removal and installation.

Torque Values

Torque values for engine mounting bolts.

Engine Removal

Step-by-step procedure for engine removal.

Engine Installation

Step-by-step procedure for engine installation.

Cylinder Head/Cylinder/Piston

Specifications

Specifications for cylinder, piston, and related parts.

Torque Values

Torque values for cylinder head and piston components.

Troubleshooting

Troubleshooting engine performance issues related to cylinder.

Cylinder Compression Test

Procedure for performing a cylinder compression test.

Cylinder Head Removal

Step-by-step guide for removing the cylinder head.

Clutch

Specifications

Technical specifications for clutch components.

Torque Values

Torque values for clutch-related fasteners.

Troubleshooting

Troubleshooting common clutch issues.

Centrifugal Clutch/Primary Drive Gear

Removal and inspection of centrifugal clutch.

Change Clutch

Procedures for changing the clutch assembly.

Gearshift Linkage

Torque Values

Torque values for gearshift linkage fasteners.

Troubleshooting

Troubleshooting gearshift linkage issues.

Gearshift Linkage Removal

Step-by-step procedure for removing the gearshift linkage.

Gearshift Linkage Installation

Procedures for installing the gearshift linkage.

Alternator/Starter Clutch

Torque Values

Torque values for alternator and starter clutch components.

Troubleshooting

Troubleshooting common issues with alternator/starter clutch.

Recoil Starter

Removal, disassembly, and assembly of the recoil starter.

Starter Clutch Assembly

Assembling the starter clutch components.

Alternator Installation

Installation of the alternator cover and components.

Crankshaft/Balancer/Transmission

Specifications

Specifications for crankshaft, balancer, and transmission parts.

Troubleshooting

Troubleshooting issues with crankshaft, balancer, transmission.

Crankcase Separation

Procedures for separating the crankcase.

Transmission Removal/Disassembly

Removing and disassembling the transmission.

Inspection

Inspecting crankshaft, gears, and shafts.

Front Wheel/Suspension/Steering

Specifications

Specifications for front wheel, suspension, steering.

Torque Values

Torque values for related components.

Troubleshooting

Troubleshooting issues with front wheel, suspension, steering.

Handlebar

Removal and installation of the handlebar.

Front Wheel

Removal and installation of the front wheel.

Front Shock Absorber

Removal, disassembly, inspection, assembly, installation of shock absorber.

Rear Wheel/Suspension

Specifications

Specifications for rear wheel and suspension components.

Torque Values

Torque values for rear wheel and suspension fasteners.

Troubleshooting

Troubleshooting rear wheel and suspension issues.

Rear Wheel

Removal and installation of the rear wheel.

Rear Shock Absorber

Removal, disassembly, inspection, assembly, installation of rear shock absorber.

Swingarm

Removal, inspection, and replacement of swingarm components.

Brake System

Specifications

Specifications for brake system components.

Torque Values

Torque values for brake system fasteners.

Troubleshooting

Troubleshooting common brake system issues.

Brake Fluid Replacement/Air Bleeding

Procedures for brake fluid replacement and bleeding.

Master Cylinder

Disassembly, inspection, and assembly of the master cylinder.

Front Driving Mechanism

Specifications

Specifications for front driving mechanism components.

Torque Values

Torque values for front driving mechanism fasteners.

Troubleshooting

Troubleshooting common front driving mechanism issues.

Front Drive Shaft

Removal, inspection, and assembly of the front drive shaft.

Front Differential

Removal, inspection, and assembly of the front differential.

Rear Driving Mechanism

Specifications

Specifications for rear driving mechanism components.

Torque Values

Torque values for rear driving mechanism fasteners.

Troubleshooting

Troubleshooting common rear driving mechanism issues.

Rear Axle Removal

Procedures for removing the rear axle.

Rear Final Drive

Removal, inspection, and assembly of the rear final drive.

Battery/Charging System

Specifications

Specifications for battery and charging system components.

Troubleshooting

Troubleshooting battery and charging system issues.

Battery

Procedures for battery removal, installation, and testing.

Battery Charging

Guidelines for charging the battery safely.

Regulator/Rectifier

Inspection and replacement of regulator/rectifier.

Ignition System

Specifications

Specifications for ignition system components.

Torque Values

Torque values for ignition system parts.

Troubleshooting

Troubleshooting ignition system problems.

Ignition System Inspection

Procedures for inspecting the ignition system.

Ignition Timing

Adjusting and checking ignition timing.

Electric Starter

Troubleshooting

Troubleshooting electric starter issues.

Starter Motor

Removal, disassembly, inspection, and assembly of the starter motor.

Starter Relay Switch

Inspection and testing of the starter relay switch.

Lights/Switches

Specifications

Specifications for bulbs and fuses.

Troubleshooting

Troubleshooting lighting and switch problems.

Headlight

Bulb replacement for headlights.

Ignition Switch

Inspection of the ignition switch.

Handlebar Switches

Inspection of handlebar switches.

Wiring Diagram

Technical Feature

Power Train

Overview of the vehicle's power train.

Limited Slip Differential

Explanation of the limited slip differential system.

OHV Valve Train

Explanation of the overhead valve train system.

Troubleshooting

Engine Does Not Start or is Hard to Start

Diagnosing and resolving starting issues.

Engine Lacks Power

Diagnosing and resolving engine power loss.

Poor Performance at Low and Idle Speeds

Troubleshooting low speed and idle performance problems.

Poor Handling

Diagnosing and resolving poor vehicle handling.

Index

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