Provides service, repair and maintenance information for 1999-2005 Honda TRX400EX models.

Includes everything you need to know to perform tune-up and routine maintenance on the engine, clutch and transmission, fuel and exhaust, ignition system, steering and suspension, wheels, brakes and tires, brakes and tires, electrical system, frame and body. Features complete wiring diagrams.

QUICK REFERENCE DATA

CHAPTER ONE/GENERAL INFORMATION
Manual organization/Basic service methods/Warnings, cautions and notes/Safety/Serial numbers/Fasterners/Shop supplies/Basic tools/Precision measuring tools/Storage

CHAPTER TWO/TROUBLESHOOTING
Operating requirements/Starting the engine/Engine spark test/Engine performance/Electrical testing/Engine starting system/Engine noise/Vehicle noise/Engine leakdown test/Clutch/Gear shift linkage and transmission/Brakes/Steering and handling

CHAPTER THREE/LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride checklist / Engine break-in / Service intervals / Tires and wheels / Battery / Lubricants / Periodic lubrication / Periodic maintenance / Engine tune-up

CHAPTER FOUR / ENGINE TOP END
Cleanliness / Cylinder head cover / Camshaft, cam chain sprocket, and tensioner / Decompressor / Cylinder head / Valves and valve components / Cylinder / Piston and piston rings / Break-in

CHAPTER FIVE / ENGINE LOWER END
Shop cleanliness / Drive sprocket / Cam chain, sprocket and guides / Engine / Crankcase (1999-2004 models)? / Crankcase seal and bearing replacement / Crankshaft / Engine break-in

CHAPTER SIX / CLUTCH, GEARSHIFT LINKAGE AND LUBRICATION SYSTEM
Right crankcase (1999-2004 models)? / Clutch / Gearshift linkage / Primary drive gear / Oil pump / Crankcase oil strainer / Oil cooler / Oil tank

CHAPTER SEVEN / TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission operation / Service notes / Mainshaft / Countershaft (1999-2004 models) / Transmission inspection / Shift drum and forks / Gearshift spindle and plate

CHAPTER EIGHT / FUEL AND EXHAUST SYSTEMS
Air cleaner / Carburetor / Carburetor inspection and repair / Carburetor adjustments / Throttle control and cable / Exhaust pipe and muffler

CHAPTER NINE / ELECTRICAL SYSTEM
Basic electrical system operating / Left crankcase cover and stator / Flywheel / Starter clutch / Starter motor / Starting system switches / Handlebar switch unit / Ignition system / Fuse / Charging system / Lights

CHAPTER TEN / FRONT SUSPENSION AND STEERING
Front wheel / Front hub / Tie rods / Steering knuckle / Control arms / Shock absorbers / Steering shaft / Handlebar / Tires and wheels

CHAPTER ELEVEN / REAR SUSPENSION
Rear wheel / Rear hub / Rear axle / Rear axle bearing holder / Driven sprocket / Drive chain / Shock absorber / Rear suspension adjustment / Shock linkage / Swing arm

CHAPTER TWELVE / BRAKES
Disc brake fundamentals / Front brake pads / Front brake caliper / Front master cylinder / Rear brake pads / Rear brake caliper / Rear master cylinder / Brake pedal / Brake discs

CHAPTER THIRTEEN / BODY
Seat and rear fender / Upper cover (1999-2004 models)? / Side covers / Front fender / Handlebar cover / Fuel tank / Fuel tank heat protector / Footpegs and mudguard / Tool box

SUPPLEMENT / 2005-ON MODEL SERVICE INFORMATION
Gear shift linkage and transmission / Periodic maintenance / Engine / Right crankcase cover / Reverse stopper plate / Transmission operation / Mainshaft / Countershaft / Reverse idle gear and shaft / Reverse switch / Taillight / Side covers / Upper headlight cover / Lower headlight cover / Front fenders

INDEX

WIRING DIAGRAMS

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