Honda TRX400FGA Manuals

Manuals and User Guides for Honda TRX400FGA. We have 2 Honda TRX400FGA manuals available for free PDF download: Service Manual, Owner's Manual

Honda TRX400FGA Service Manual

Honda TRX400FGA Service Manual (514 pages)

2004-2007

Brand: Honda | Category: Offroad Vehicle | Size: 59.16 MB

Table of Contents

A few Words about Safety
2
Service Information
2
Important Safety Precautions
2
Contents
3
Symbols
4
General Information
5
Service Rules
6
Model Identification
6
Model Identification Label
7
Frame Serial Number
7
Engine Serial Number
7
Carburetor Identification Number
7
Colour Label
8
General Specifications
9
Lubrication System Specifications
11
Fuel System Specifications
11
Cylinder Head/Valve/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
Front Wheel/Suspension/Steering Specifications
14
Rear Wheel/Suspension Specifications
14
Brake System Specifications
14
Front Driving Mechanism Specifications
15
Rear Driving Mechanism Specifications
15
Battery/Charging System Specifications
15
Ignition System Specifications
15
Lights/Meters/Switches Specifications
16
Standard Torque Values
17
Engine & Frame Torque Values
17
Lubrication & Seal Points
23
Cable & Harness Routing
28
Source of Emissions
43
Exhaust Emission Control System
43
Crankcase Emission Control System
43
Noise Emission Control System
43
Emission Control Information Label (U.S.A. Only)
44
Technical Feature
45
GPS Navigation Meter (GPS Type)
46
Global Positioning System (GPS)
46
Structure/Function
47
Navigation System
47
Compass
47
Automatic Clock Adjustment
47
Frame/Body Panels/Exhaust System
49
Frame/Body Panels/Exhaust System Service Information
50
Frame/Body Panels/Exhaust System Troubleshooting
50
Body Panel Locations
51
Seat/Side Cover Removal
52
Tank Side Covers and Tank Top Cover
52
Seat/Side Cover Installation
53
Front Carrier/Bumper/Front Fender Removal
54
Front Carrier/Bumper/Front Fender Disassembly
55
Front Carrier/Bumper/Front Fender Installation
56
Rear Luggage Carrier/Rear Fender Removal
58
Center Mudguard
59
Rear Luggage Carrier/Rear Fender Disassembly
60
Rear Luggage Carrier/Rear Fender Installation
61
Exhaust System Removal
62
Exhaust Pipe
62
Muffler
62
Exhaust System Installation
63
Maintenance
65
Maintenance Service Information
66
Maintenance Schedule
68
Fuel Line
69
Throttle Operation
69
Carburetor Choke
70
Air Cleaner
70
Air Cleaner Housing Drain Hose
72
Spark Plug
72
Spark Plug Inspection
73
Reusing a Spark Plug
73
Replacing a Spark Plug
73
Valve Clearance
74
Engine Oil Level Check
76
Engine Oil Change
77
Engine Oil Filter
78
Engine Idle Speed
78
Drive Shaft Boots
79
Rear Final Gear Case Oil and Differential Oil
79
Brake Fluid
81
Brake Shoes Wear
82
Brake System
82
Front Brake
82
Rear Brake
82
Skid Plate, Engine Guard
84
Suspension
84
Swingarm Bearings
85
Spark Arrester Cleaning
85
Nuts, Bolts, Fasteners
86
Wheels/Tires
86
Steering Shaft Holder Bearing
86
Steering System
87
Lubrication System
89
Lubrication System Diagram
90
Lubrication System Service Information
91
Lubrication System Tools
92
Lubrication System Troubleshooting
94
Oil Pressure Check
95
Front Crankcase Cover Removal
96
Oil Pressure Relief Valve Inspection
96
Relief Valve Inspection
97
Oil Feed Pipe Inspection
98
Bearing Replacement
99
Oil Pump Removal
102
Oil Pump Disassembly
102
Oil Pump Inspection
103
Oil Pump Assembly
104
Oil Pump Installation
106
Oil Cooler Removal
107
Cooling Fan Removal
108
Cooling Fan Disassembly
109
Cooling Fan Assembly
110
Cooling Fan Installation
111
Oil Cooler Installation
112
Fuel System
115
Fuel System Components
116
Fuel System Service Information
117
Fuel System Troubleshooting
118
Air Cleaner Housing Removal/Installation
119
Sub-Air Cleaner Removal
120
Sub-Air Cleaner Cleaning
120
Carburetor Removal
121
Sub-Air Cleaner Installation
121
Carburetor Disassembly/Inspection
122
Starting Enrichment (SE) Valve Inspection
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
Carburetor Installation
134
Pilot Screw Adjustment
137
Idle Drop Procedure
137
High Altitude Adjustment
138
Fuel Tank Removal
139
Fuel Strainer Screen Cleaning
141
Fuel Tank Installation
142
Engine Removal/Installation
145
Engine Removal/Installation System Components
146
Engine Removal/Installation Service Information
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 Tools
162
Cylinder Head/Valve/Camshaft Troubleshooting
163
Cylinder Compression
164
Cylinder Head Cover Removal/Disassembly
164
Cylinder Head Removal
166
Rocker Arm/Shaft Inspection
166
Cylinder Head Disassembly
167
Cylinder Head Inspection
168
Valve/Valve Guide
169
Valve Guide Replacement
170
Valve Seat Inspection/Refacing
171
Camshaft Removal
173
Camshaft Inspection
175
Cam Follower
176
Cam Chain Tensioner
176
Camshaft Installation
177
Cylinder Head Assembly
179
Cylinder Head Installation
180
Cylinder Head Cover Assembly/Installation
182
Cylinder/Piston
185
Cylinder/Piston System Components
186
Cylinder/Piston Service Information
187
Cylinder/Piston Troubleshooting
187
Cylinder/Piston Removal
188
Piston Disassembly
188
Cylinder Inspection
189
Piston/Piston Ring
190
Cylinder Stud Bolt Replacement
191
Cylinder/Piston Installation
192
Piston Assembly
192
Centrifugal Clutch
195
Centrifugal Clutch Component Location
196
Centrifugal Clutch Service Information
197
Centrifugal Clutch Troubleshooting
198
Centrifugal Clutch Removal
199
Centrifugal Clutch Inspection
200
One-Way Clutch
200
Clutch Drum
200
Weight Lining/Weight Spring/Clutch Spring
201
Alternator/Starter Clutch
207
Alternator/Starter Clutch System Components
208
Alternator/Starter Clutch Service Information
209
Alternator/Starter Clutch Troubleshooting
209
Recoil Starter Removal
210
Recoil Starter Disassembly
210
Recoil Starter Assembly
212
Alternator Stator
215
Recoil Starter Installation
215
Alternator Cover Removal
215
Alternator Cover Installation
216
Stator and Ignition Pulse Generator Removal/Installation
216
Flywheel/Starter Clutch Removal
218
Starter Clutch Disassembly/Inspection
219
Starter Clutch Assembly
220
Starter Clutch Installation
221
Sub-Transmission/Gearshift Linkage
223
Sub-Transmission/Gearshift Linkage System Components
224
Sub-Transmission/Gearshift Linkage Service Information
225
Sub-Transmission/Gearshift Linkage Tools
226
Sub-Transmission/Gearshift Linkage Troubleshooting
227
Rear Crankcase Cover Removal
228
Rear Crankcase Cover Installation
231
Sub-Transmission/Gearshift Linkage Disassembly
234
Sub-Transmission/Gearshift Linkage Assembly
237
Crankshaft/Automatic Transmission
239
Crankshaft/Automatic Transmission System Components
240
Crankshaft/Automatic Transmission Service Information
241
Crankshaft/Automatic Transmission Tools
241
Crankshaft/Automatic Transmission Troubleshooting
243
Crankcase Separation
245
Oil Strainer Cleaning
247
Breather Separator Replacement
247
Automatic Transmission Removal
248
Automatic Transmission Inspection
248
Automatic Transmission Installation
249
Crankshaft/Balancer Removal
249
Crankshaft/Balancer Inspection
250
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 System Components
258
Front Wheel/Suspension/Steering Service Information
259
Front Wheel/Suspension/Steering Tools
260
Front Wheel/Suspension/Steering Troubleshooting
261
Handlebar Removal
262
Handlebar Installation
264
Throttle Housing Disassembly
266
Throttle Housing Assembly
267
Front Wheel Removal/Installation
268
Tires Removal
268
Tire Repair
269
Tire Assembly
271
Wheel Hub/Knuckle Removal
271
Wheel Hub/Knuckle Inspection
273
Ball Joint Replacement
275
Ball Joint Installation
276
Front Shock Absorber Removal
278
Front Shock Absorber Inspection
278
Front Shock Absorber Installation
278
Suspension Arm Removal
279
Suspension Arm Inspection
280
Suspension Arm Installation
281
Steering Shaft Removal
282
Steering Shaft Inspection
283
Steering Shaft Installation
285
Tie-Rod Removal
287
Tie-Rod Inspection
287
Tie-Rod Disassembly/Assembly
288
Tie-Rod Installation
288
Rear Wheel/Suspension
289
Rear Wheel/Suspension System Components
290
Rear Wheel/Suspension Service Information
291
Rear Wheel/Suspension Tools
292
Rear Wheel/Suspension Troubleshooting
293
Rear Wheel Removal/Installation
294
Rear Shock Absorber Removal
294
Rear Shock Absorber Inspection
295
Pivot Bearing Replacement
295
Swingarm Removal
296
Rear Shock Absorber Installation
296
Swingarm Inspection
298
Swingarm Pivot Bearing Replacement
299
Swingarm Installation
300
Brake System Component Location
304
Brake System Service Information
305
Brake System Tools
306
Brake System Troubleshooting
306
Brake Fluid Replacement/Air Bleeding
307
Brake Fluid Draining
307
Brake Fluid Filling
307
Brake Bleeding
308
Brake Hose/Brake Pipe/Breather Hose Inspection
309
Front Master Cylinder Removal
309
Front Master Cylinder Disassembly
310
Front Master Cylinder Inspection
311
Front Master Cylinder Assembly
311
Front Brake Shoes/Drum
314
Brake Drum Removal
314
Brake Shoe Replacement
315
Water Seal Inspection
316
Water Seal Replacement
316
Front Brake Panel Inspection
317
Brake Drum Installation
317
Front Wheel Cylinder/Brake Panel Disassembly
318
Front Wheel Cylinder/Brake Panel Inspection
320
Front Wheel Cylinder/Brake Panel Assembly
320
Rear Brake Inspection
323
Dust Seal Replacement
324
Brake Panel Disassembly
325
Brake Panel Bearing Replacement
326
Brake Panel Assembly
328
Brake Pedal Removal
331
Brake Pedal Installation
332
Front Driving Mechanism
333
Front Driving Mechanism System Components
334
Front Driving Mechanism Service Information
335
Front Driving Mechanism Tools
336
Front Driving Mechanism Troubleshooting
338
Front Drive Shaft Removal
339
Front Drive Shaft Disassembly/Inspection
340
Front Drive Shaft Assembly
342
Front Drive Shaft Installation
344
Differential Removal
346
Differential Disassembly/Inspection
348
Propeller Shaft Inspection
348
Operation Check
349
Backlash Inspection
349
Differential Case Disassembly
350
Gear Tooth Contact Pattern Check
351
Differential Inspection
352
Differential Disassembly
353
Differential Components Inspection
354
Ring Gear
354
Differential Housing/Face Cam/Cam Followers
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
Rear Driving Mechanism System Components
368
Rear Driving Mechanism Service Information
369
Rear Driving Mechanism Tools
370
Rear Driving Mechanism Troubleshooting
372
Rear Axle Removal
373
Rear Axle Inspection
374
Final Drive Removal
375
Final Drive Inspection
376
Final Drive Disassembly/Inspection
377
Final Gear Case Disassembly
378
Pinion Gear Bearing/Shim Replacement
381
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 System Diagram
392
Battery/Charging System Service Information
393
Battery/Charging System Troubleshooting
394
Battery Removal/Installation
395
Battery Voltage Inspection
395
Battery Testing
395
Battery Charging
396
Charging System Inspection
398
Current Leakage Inspection
398
Charging Voltage Inspection
398
Alternator Charging Coil Inspection
399
Regulator/Rectifier
399
Wire Harness Inspection
399
Regulator/Rectifier Removal/Installation
400
Ignition System
401
Ignition System Component Location
402
Ignition System System Diagram
402
Ignition System Service Information
403
Ignition System Troubleshooting
404
Ignition System Inspection
405
Ignition Coil Primary Peak Voltage
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 Troubleshooting
412
Starter Motor Removal
414
Starter Motor Disassembly/Inspection
414
Starter Motor Assembly
417
Starter Motor Installation
419
Starter Relay Switch Operation Inspection
420
Starter Relay Switch Circuit Inspection
420
Starter Relay Switch Function Inspection
420
Diode Inspection
421
Lights/Meters/Switches
423
Lights/Meters/Switches Component Location
424
Lights/Meters/Switches Service Information
425
Headlight Bulb Replacement
426
Headlight Removal/Installation
427
Tail/Brake Light Bulb Replacement
427
Tail/Brake Light Removal/Installation
428
Accessory Socket Inspection
428
Accessory Socket Replacement
429
Ignition Switch Inspection
429
Ignition Switch Removal/Installation
429
Handlebar Switch Inspection
430
Carburetor Heater/Air Temperature Switch System Inspection
431
Carburetor Heater Inspection
431
Air Temperature Switch Inspection
432
Combination Meter/Rear Vehicle Speed Sensor (VSS)
433
Power/Ground Line Inspection
433
Speedometer/Rear VSS
433
Combination Meter Removal/Installation
434
Oil Temperature Sensor/Cooling Fan
435
Oil Temperature Indicator System Inspection
435
Oil Temperature Indicator Does Not Come On, When the Oil Is over the Specified Temperature
436
Cooling Fan System Inspection
437
Cooling Fan Motor Does Not Start, When the Oil Is over the Specified Temperature
437
Cooling Fan Does Not Stop
438
Oil Temperature Sensor Inspection
439
GPS Receiver Inspection
440
GPS Indicator Blinks (Communication Error)
441
Brake Light Switch
443
Front Brake Lever
443
Rear Brake Lever
443
Rear Brake Pedal
443
Front Brake Switch
444
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 Chart
447
Selectable 4WD System Troubleshooting
447
Problem Code 2: Front Vehicle Speed Sensor (VSS)
448
Problem Code 3: Rear Vehicle Speed Sensor (VSS)
450
Problem Code 4: System Voltage
452
Problem Code 5: Front Final Clutch System
452
Rear Vehicle Speed Sensor (VSS) Removal
454
Rear Vehicle Speed Sensor (VSS) Installation
454
Hondamatic
457
Hondamatic Component Location
458
Hondamatic Service Information
459
Hondamatic Connector Location
460
Hondamatic Circuit Diagram
461
Before Starting Troubleshooting
462
Self-Diagnostic Function
462
Retrieval/Erasure of Problem Code
463
Problem Code Blink Duration
464
To Erase the Problem Code
464
Erasure Confirmation Blink Duration
464
Initial Setting Procedure
465
Troubleshooting Chart
468
Diagnostic Troubleshooting
469
Problem Code 1: Ignition Pulse Generator System
469
Problem Code 2: Vehicle Speed Sensor (VSS) System
471
Problem Code 3: Gear Position Switch System
473
Problem Code 4: Throttle Position (TP) Sensor System
474
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 System
484
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 CPU
487
Problem Code 12: ECM Motor Driver Circuit
488
Problem Indicated (Mode 1), but no Code Is Retrievable
490
Problem Not Detected by ECM
491
Drive/Neutral/Reverse Switch Inspection
494
Drive/Neutral/Reverse Switch Replacement
494
ESP Shift Switch Inspection
495
Mode Select Switch Inspection
496
Mode Select Switch Replacement
496
Throttle Position (TP) Sensor Inspection
497
Throttle Position (TP) Sensor Replacement
498
Angle Sensor Inspection
498
Angle Sensor Replacement
499
Sensor Resistance
499
Control Motor Removal/Installation
500
Sensor Preload
500
Engine Control Module (ECM) Removal/Installation
502
Wiring Diagrams
503
Standard Type
504
GPS Type
505
Troubleshooting
506
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
Index
512

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Honda TRX400FGA Owner's Manual

Honda TRX400FGA Owner's Manual (287 pages)

FOURTRAX RANCHER AT/WITH GPScape

Brand: Honda | Category: Offroad Vehicle | Size: 8.11 MB

Table of Contents

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