Clymer Honda Trx400ex Fourtrax and Sportrax 1999-2005

by Bogart, Jay

• ISBN13: 9780892879915
• ISBN10: 0892879912
• Format: Paperback
• Copyright: 2006-02-28
• Publisher: Clymer Pubns

Table of Contents

Quick Reference Data	ix
General Information	1	(28)
Manual organization
Basic service methods
Warnings, cautions and notes
Safety
Serial numbers
Fasteners
Shop supplies
Basic tools
Precision measuring tools
Storage
Troubleshooting	29	(13)
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
Lubrication, Maintenance and Tune-Up	42	(30)
Pre-ride checklist
Engine break-in
Service intervals
Tires and wheels
Battery
Lubricants
Periodic lubrication
Periodic maintenance
Engine tune-up
Engine Top End	72	(40)
Cleanliness
Cylinder head cover
Camshaft, cam chain sprocket, and tensioner
Decompressor
Cylinder head
Valves and valve components
Cylinder
Piston and piston rings
Break-in
Engine Lower End	112	(21)
Shop cleanliness
Drive sprocket
Cam chain, sprocket and guides
Engine
Crankcase (1999-2004 models)
Crankcase seal and bearing replacement
Crankshaft
Engine break-in
Clutch, Gearshift Linkage and Lubrication System	133	(20)
Right crankcase cover (1999-2004 models)
Clutch
Gearshift linkage
Primary drive gear
Oil pump
Crankcase oil strainer
Oil cooler
Oil tank
Transmission and Internal Shift Mechanism	153	(13)
Transmission operation
Service notes
Mainshaft
Countershaft (1999-2004 models)
Transmission inspection
Shift drum and forks
Gearshift spindle and plate
Fuel and Exhaust Systems	166	(19)
Air cleaner
Carburetor
Carburetor inspection and repair
Carburetor adjustments
Throttle control and cable
Exhaust pipe and muffler
Electrical System	185	(32)
Basic electrical system operation
Left crankcase cover and stator
Flywheel
Starter clutch
Starter motor
Starting system switches
Handlebar switch unit
Ignition system
Fuse
Charging system
Lights
Front Suspension and Steering	217	(23)
Front wheel
Front hub
Tie rods
Steering knuckle
Control arms
Shock absorbers
Steering shaft
Handlebar
Tires and wheels
Rear Suspension	240	(25)
Rear wheel
Rear hub
Rear axle
Rear axle bearing holder
Driven sprocket
Drive chain
Shock absorber
Rear suspension adjustment
Shock linkage
Swing arm
Brakes	265	(27)
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
Body	292	(7)
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	299	(19)
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	318	(4)
Wiring Diagrams	322