Honda trx400ex service manual free download

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This is your only chance to own a Street Legal 4 wheeler. Currently titles and registered in KY. I have a Honda trx90 I got from a buddy for free he said it needed a carb so I put his old carb back on it to try to get something out of it and it does not have any Spark. I already replaced the ignition coil I don't know much about four wheelers but I am a technician so I do know my way around a motor any electrical help would be wonderful or specs I don't have the best digital multimeter either.

Hey guys I'm new to the Forum I just got a Honda trx90 looking to make it go a little bit quicker I don't know much about four wheelers but I am a technician at a dealership so I know my way around a motor. Manufacturer Logos. Quick Links. Table of Contents.

Previous Page. Next Page. Chapters General Information 1. Honda Moly 60 U. Use the special tools designed for this product to avoid damage and incorrect assembly. FRAME The engine serial number is stamped on the lower left The frame serial number is stamped o n the front side of the crankcase. Current leakage Equivalent commercially available in U. Not available in U. Alternative tool REF. Page Emission Control Systems Carbon monoxide does not react in the same way, but it is toxic.

Honda Motor Co. Page 29 2. Raise the seatlfender assembly up and remove it. Remove the screw and two trim clips. Release the side cover from the three tabs of the front fender by sliding it forward and remove the side cover. Installation is in the reverse order removal. Disconnect the fuel tube from the fuel valve. Unhook the mounting straps. Remove the two mounting bolts and the fuel tank. Page 33 Remove the five screws, nut and the mud guard. Remove the washer bolt from the footpeg bottom and the inner mud guard stay.

Remove the bolt and washer and the outer mud guard stay from the stay hole in the footpeg. Remove the two socket bolts and washers and the footpeg. Remove the seatkear fender page Remove the upper and lower muffler mounting bolts and washers between the muffler and frame. Remove the muffler.

Page 35 0. Page Note In the interest of safety, we recommend these items be serviced only by your Honda dealer. NOTES 1. Service more frequently if the A N is ridden in dusty areas, sand or snow. Service more frequently if the ATV is ridden in very wet or muddy conditions. Check the fuel line for deterioration, damage or leak- age. Replace the fuel line if necessary. Check for any deterioration or damage to the throttle cable. Check that the throttle lever for smooth opera- tion.

Remove the seathear fender assembly page Release the six retaining clips from the air cleaner housing covet and remove the cover. This position can be obtained by confirming that there is slack in the sub-rocker arm.

Page Engine Oil If the oil level is near or below the lower level mark, and the recommended engine oil up to the upper level mark. NOTE: The engine takes about 1. Because only a por- tion of that oil is held in the oil tank, you cannot add the full amount initially. Wear insulated gloves. Drain the engine oil page Disconnect the oil pipe from the lower side of the oil tank by loosening the flare nut. Page Drive Chain Inspect and replace the sprockets necessary.

Some commercially available chain lubricants may contain solvents which could damage the O-rings. Replace if necessary. Never use worn chain on new sprockets.

Both chain and sprockets must be in good condition, or the new replacement parts will wear rapidly. Check the attachment bolt and nuts on the drive and driven sprockets. Check the fluid level in the rear brake reservoir.

Loosen the lock nut and turn the adjusting nut. After adjustment is complete, tighten the lock nut securely while holding the adjusting nut. Check the clutch operation. Touching the h o t exhaust may result in severe burns. Remove the three bolts and the spark arrester with the gasket. B O L T S Use a brush to remove carbon deposits from the screen mesh, being careful not to damage the screen mesh. Page 55 MEMO Page 57 1. Remove the three mounting bolts and the oil pump.

Remove the gasket and two dowel pins. Remove the following: - pump shaft - drive pin Set the pump assembly onto the crankcase and tight- en the three bolts securely. Remove the two mounting bolts and the oil cooler. Installation is in the reverse order of removal Replace the 0- rings with new ones and coat Gasoline is extremely flammable and is explosive under certain conditions.

If the engine must be running to do some work make sure the area is well-ventilated. Place and approved fuel container under the drain tube. Loosen the drain screw and drain the carbure- tor. Remove the air vent tube from the heat protector and the fuel t u b e f r o m t h e heat protector rubber. The vacuum should maintained.

Air should not flow through the valve ports when the vacuum is applied, and should flow when the vacu- um is not applied. Remove the O-ring from the body groove. Check the throttle valve for scoring, scratches or damage. Check the boot for deterioration or damage. After ' 0 0 Remove the float pin by gently tapping with a suitable pin driver O.

Check each jet for wear or damage. Check the pilot screw for wear or damage. Clean the jets with cleaning solvent and blow open with compressed air. Perform the pilot screw adjustment if new pilot screw installed. Install the float chamber, being careful not to pinch the boot and tighten the four screws. Insert the link arm shaft through the throttle link arm, spring, carburetor body, washer and valve arm while hanging the spring ends as shown.

Align the screw holes in the valve arm and shaft and tighten the screw with the washer. Secure the with the screw by aligning its hole stay and boss. STAY Turn the throttle stop screw to align the butterfly throttle valve with the edge of the outside by-pass hole in the carburetor. Install the throttle linkage cover by aligning the tab with the slit in the carburetor and secure it with the screws.

Use a tachometer with graduations of 50 rpm or smaller that w i l l accurately indicate a 50 rpm change. Disconnect the crankcase breather tube and remove the crankcase breather storage tank f r o m the air cleaner connecting tube.

Remove the mounting bolt. Loosen the connecting tube band and intake duct band screws. Page 81 6. When removing and installing the engine, tape the frame around the engine beforehand for frame protection. The following components require engine removal for service: -transmission including shift fork, drum and shift spindle section Other components can be serviced with the engine installed in the frame.

Loosen the rear axle for maximum drive chain slack page Remove the two bolts, sprocket cover, sprocket pro- tector and clamp. Disconnect the crankcase breather tube from the engine. Release the brake lock cable from the cable guide by removing the mounting bolt. Loosen the clutch cable lock nut. The Honda ex manual contains the following. Handy thumb-tabs put the chapter you need right at your fingertips.

Detailed substeps expand on service procedure information. Notes, cautions and warnings throughout each chapter pinpoint critical information.

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