Honda TRX400FW Manuals

Manuals and User Guides for Honda TRX400FW. We have 1 Honda TRX400FW manual available for free PDF download: Service Manual

Honda TRX400FW Service Manual (371 pages)

Brand: Honda | Category: Offroad Vehicle | Size: 37.32 MB

Important Safety Notice
2
Contents
3
General Information: Contents
5
General Safety
5
Service Rules
6
Model Identification
7
Specifications - General
8
Specifications - Lubrication/Fuel System
10
Specifications - Cylinder Head/Valves/Camshaft/Piston
11
Specifications - Clutch/Gearshift Linkage
12
Specifications - Crankshaft/Transmission
13
Specifications - Front/Rear Wheel/Suspension/Steering/Brakes/Front Driving Mechanism
14
Specifications - Rear Driving Mechanism, Battery/Charging System, Ignition System, Electric Starter
15
Specifications - Light/Switches
16
Torque Values
17
Tools
20
Lubrication and Seal Point
22
Cable and Harness Routing
25
Frame/Body Panels/Exhaust System: Contents, Service Information, Troubleshooting
31
Body Panel Locations
32
Seat/Side Cover Removal
33
Seat/Side Cover Installation
34
Front Carrier/Bumper/Front Fender Removal
35
Front Carrier/Bumper/Front Fender Disassembly
36
Rear Carrier/Rear Fender Removal
39
Rear Carrier/Rear Fender Disassembly
40
Rear Carrier/Rear Fender Installation
41
Handlebar Cover Removal
42
Handlebar Cover Installation
43
Exhaust System Removal
43
Muffler
43
Exhaust System Installation
44
Maintenance: Contents, Service Information
45
Maintenance Schedule
47
Fuel Line
48
Throttle Operation
48
Carburetor Choke
49
Air Cleaner
49
Air Cleaner Housing Drain Tube
50
Spark Plug
51
Valve Clearance
52
Engine Oil and Oil Filter
53
Oil Level Inspection
53
Engine Oil and Filter Change
54
Engine Idle Speed
55
Final Gear Case Oil and Differential Oil
56
Oil Change
57
Brake Fluid
58
Brake Shoe Wear
58
Brake System
59
Reverse Lock System
60
Skid Plates/Engine Guard
61
Clutch System
61
Drive Shaft Boots Inspection
61
Suspension
62
Spark Arrester: Cleaning
62
Nuts, Bolts, Fasteners
63
Wheels/Tires
63
Steering Shaft Holder Bearing
63
Steering System
64
Toe
64
Lubrication System Diagram
66
Lubrication System: Contents, Service Information, Troubleshooting
67
Oil Cooler Removal, Disassembly, Inspection
68
Oil Cooler Assembly, Installation
69
Cooling Fan Motor/Shroud Removal
70
Cooling Fan Motor/Shroud Disassembly
71
Cooling Fan Motor/Shroud Assembly
72
Cooling Fan Motor/Shroud Installation
73
Oil Pump Removal/Disassembly, Inspection
74
Oil Pump Assembly
76
Oil Pump Installation
77
Relfief Valve Disassembly, Inspection, Assembly
77
Oil Strainer Screen Cleaning
78
Fuel System: Contents, Service Information
81
Fuel System: Specifications
82
Fuel System: Troubleshooting
83
Air Cleaner Housing Removal, Installation
84
Carburetor Removal
85
Carburetor Disassembly
86
Starting Enrichment Valve
86
Float and Jets
86
Primer Knob
88
Diaphragm/Vacuum Piston
88
Air Cut off Valve
89
Carburetor Assembly
90
Float Level Inspection
93
Carburetor Installation
94
Starting Enrichement Valve
94
Pilot Screw Adjustment
96
High Altitude Adjustment
97
Fuel Tank Removal
98
Fuel Strainer Screen
98
Fuel Tank Installation
99
Engine Removal/Installation: Contents, Service Information
103
Engine Removal
104
Engine Installation
106
Cylinder Head/Cylinder/Piston: Contents, Service Information
111
Cylinder Head/Cylinder/Piston: Troubleshooting
113
Cylinder Compression Test
114
Cylinder Head Removal/Cover Removal
114
Cylinder Head Removal
115
Rocker Arm Holder Disassembly/Inspection
116
Cylinder Head Disassembly, Inspection
117
Valve Spring
117
Valve/Valve Guide
118
Valve Guide Replacement
119
Valve Seat Inspection/Refacing
119
Valve Seat Refacing
120
Cylinder Head Assembly
122
Cylinder Head Installation
123
Rocker Arm Holder Assembly
123
Rocker Arm Holder Installation
124
Cylinder/Piston Removal
125
Cylinder/Piston Inspection
126
Cylinder/Piston Installation
128
Camshaft/Cam Chain Tensioner
130
Cam Chain Tensioner Removal
131
Cam Chain Tensioner Inspection
132
Cam Chain Tensioner Installation
133
Camshaft Installation
133
Cam Chain Tensioner Lifter
135
Clutch: Contents, Service Information
139
Clutch: Troubleshooting
140
Front Crankcase Cover Removal
141
Bearing Replacement
141
Centrifugal Clutch/Primary Drive Gear Removal
142
Centrifugal Clutch/Primary Drive Gear Inspection
143
Centrifugal Clutch/Primary Drive Gear Assembly
146
Centrifugal Clutch/Primary Drive Gear Installation
148
Change Clutch Removal
149
Change Clutch Inspection
151
Change Clutch Installation
153
Front Crankcase Cover Installation
155
Gearshift Linkage: Contents, Service Information, Troubleshooting
159
Gearshift Linkage Removal
160
Gearshift Linkage Inspection, Installation
162
Reverse Stopper Shaft Removal
165
Alternator/Starter Clutch
168
Alternator/Starter Clutch: Contents, Service Information, Troubleshooting
169
Recoil Starter Removal, Disassembly
170
Recoil Starter Assembly
171
Recoil Starter Installation
173
Alternator Removal
174
Alternator Cover Disassembly
174
Flywheel/Starter Clutch Removal
176
Rear Crankcase Cover Removal
176
Starter Clutch Inspection/Disassembly
177
Starter Clutch Assembly
178
Rear Crankcase Cover Installation
179
Flywheel/Starter Clutch Installation
180
Alternator Installation/Assembly
181
Crankshaft/Balancer/Transmission Overview
184
Crankshaft/Balancer/Transmission: Contents, Service Information
185
Crankshaft/Balancer/Transmission: Troubleshooting
187
Crankcase Separation
188
Transmission Removal/Disassembly
188
Crankcase Bearing Locations
193
Reverse Idle Shaft
194
Crankshaft/Balancer Removal
196
Crankshaft/Balancer Inspection
197
Crankshaft/Balancer Installation
198
Crankcase Assembly
199
Front Wheel/Suspension/Steering: Contents, Service Information
203
Front Wheel/Suspension/Steering: Troubleshooting
204
Handlebar Removal/Installation
205
Throttle Housing Disassembly
207
Throttle Housing Assembly
208
Front Wheel Removal/Installation
209
Tires Removal
209
Tire Repair
211
Tire Assembly
212
Tie-Rod/Knuckle Removal
213
Tie-Rod/Knuckle Inspection
215
Knuckle Bearing Inspection/Replacement
216
Knuckle Installation
217
Tie-Rod Assembly, Installation
218
Upper/Lower Arms Removal, Inspection
220
Upper/Lower Arms Installation
221
Steering Shaft Removal
221
Steering Shaft Inspection
222
Steering Shaft Installation
224
Front Shock Absorber Removal, Disassembly, Inspection
226
Front Shock Absorber Assembly
227
Front Shock Absorber Installation
228
Rear Wheel/Suspension: Overview
230
Rear Wheel/Suspension: Contents, Service Information
231
Rear Wheel/Suspension: Troubleshooting
232
Rear Wheel Removal, Installation
233
Rear Shock Absorber Removal
233
Rear Shock Absorber Disassembly, Inspection
234
Rear Shock Absorber Assembly
235
Rear Shock Absorber Installation
236
Swingarm Removal
236
Swingarm Inspection
238
Pivot Bearing Replacement
238
Swingarm Installation
239
Brake System Overview
242
Brake System: Contents, Service Information
243
Brake System: Troubleshooting
244
Brake Fluid Replacement/Air Bleeding
245
Brake Fluid Draining
245
Brake Bleeding
246
Brake Hose/Brake Pipe/Breather Tube Inspection
246
Master Cylinder Disassembly
247
Master Cylinder Inspection/Assembly
248
Brake Shoes/Wheel Cylinder/Adjuster Disassembly
249
Wheel Cylinder/Adjuster Inspection
252
Front Brake Panel Inspection
252
Front Brake Waterproof Seal Inspection/Replacement
253
Front Brake Waterproof Seal Assembly
254
Rear Brake Removal/Disassembly
257
Rear Brake Assembly/Installation
261
Brake Pedal Removal/Installation
265
Front Driving Mechanism Overview
268
Front Driving Mechanism: Contents, Service Information
269
Front Driving Mechanism: Troubleshooting
270
Front Drive Shaft Removal
271
Front Drive Shaft Inspection/Disassembly
272
Front Drive Shaft Assembly
273
Front Drive Shaft Installation
276
Front Differential Removal
277
Backlash/Front Differential Inspection
278
Differential Case Disassembly
279
Gear Tooth Contact Pattern Check
280
Differential Assembly Inspection
282
Differential Disassembly
283
Differential Inspection
284
Drive Pinion Removal
285
Drive Pinion Disassembly/Assembly
286
Case Bearing Replacement
287
Drive Pinion Installation
288
Differential Assembly
289
Differential Case Assembly/Installation
292
Rear Driving Mechanism Overview
296
Rear Driving Mechanism: Contents, Service Information
297
Rear Driving Mechanism: Troubleshooting
298
Rear Axle Removal
299
Rear Axle Inspection
300
Rear Final Drive
302
Gear Case Removal/Inspection
302
Backlash Inspection
303
Gear Case Disassembly
303
Gear Tooth Pattern Check
304
Gear Case Assembly Overview
311
Gear Case Installation
312
Rear Axle Installation
313
Rear Drive Shaft Removal/Inspection/Installation
316
Battery/Charging System Overview
318
Battery/Charging System: Contents, Service Information
319
Battery/Charging System Troubleshooting
321
Battery Removal/Installation
322
Voltage Inspection
322
Battery Testing
322
Battery Charging
323
Charging System
325
Leakage/Regulated Voltage Inspection
325
Alternator Charging Coil Inspection
326
Regulator/Rectifier: Voltage Inspection
326
Regulator/Rectifier Replacement
327
Ignition System: Overview
328
Ignition System: Contents, Service Information
329
Ignition System Troubleshooting
331
Ignition System Inspection
332
Ignition Primary Peak Voltage
332
Ignition Pulse Generator Peak Voltage
333
AC Sensor Line Inspection
334
Ignition Coil Inspection
334
Ignition Coil Removal/Installation
335
Ignition Pulse Generator Inspection/Removal/Installation
335
Ignition Timing
336
Electric Starter Overview
338
Electric Starter: Contents, Service Information
339
Electric Starter: Troubleshooting
340
Starter Motor Removal/Disassembly/Inspection
341
Starter Motor Assembly
343
Starter Motor Installation
345
Starter Relay Switch: Operation Inspection
345
Voltage/Continuity Inspection
345
Diode Removal/Inspection/Installation
346
Lights/Switches: Overview
348
Lights/Switches: Contents, Service Information, Troubleshooting
349
Headlight Bulb Replacement
351
Headlight Bulb Removal/Installation
352
Assist Headlight: Bulb Replacement
352
Taillight Bulb Replacement/Removal/Installation
353
Indicator Lamps Bulb Replacement
354
Ignition Switch Inspection
354
Handlebar Switches
355
Neutral/Reverse Switch Inspection
355
Neutral/Reverse Switch Removal/Installation
356
Cooling Fan Control Unit: System Inspection
356
Oil Thermo Sensor Inspection/Removal/Installation
357
Wiring Diagram
360
Technical Feature
361
Power Train
361
Limited Slip Differential
362
OHV Valve Train
363
Gearshift Mechanism
364
Troubleshooting
365
Engine Does Not Start or Is Hard to Start
365
Engine Lacks Power
366
Poor Performance at High Speeds
368
Poor Handling
368
Index
369

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Honda TRX400FW Service Manual (371 pages)

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