HONDA TRXFW SERVICE MANUAL Pdf Download | ManualsLib.Honda TRX400EX SportTrax 400EX Owner's Manual

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400ex repair manual free download.Honda TRX400FW Service Manual

 

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WordPress Shortcode. Like Liked. Full Name Comment goes here. Are you sure you want to Yes No. Be the first to like this. No Downloads. Views Total views. Actions Shares. No notes for slide. Camshaft sprocket Inspect the teeth of each camshaft sprocket for wear or damage. If they are worn or damaged, replace the camshaft and cam chain as a set. Automatic decompression Move the automatic decompression weight by hand to inspect if it is operating smoothly.

If the automatic decompression weight does not operate smoothly, replace it with a new one. Cam wear Check the camshaft for wear or damage. Replace a camshaft if the cams are worn to the service limit. Camshaft journal wear Inspect the camshaft journal wear in the following procedures:.

Special tool A : — Plastigauge 0.

 

Honda TRXEX Sportrax Service Repair Manual.Honda TRX400EX FOURTRAX 2001 Manuals

 

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You can change your ad preferences anytime. Upcoming SlideShare. Like this document? Becarefulnotto Rotate the crankshaft counterclockwise one turn and let the sprocket remove the other cam sprocket bolt. Remove the shafts, sealing washers, sub-rocker arms and wave washers. Hold the cylinder head cover securely and loosen the rocker arm shafts, being careful to damage the If the rocker arm slipper surface is worn or damaged, check the camshaft cam lobe and oil passages.

Check both cams for wear or damage. Check the valve for bending, burning or abnormal wear. Measure each valve stem O. Use temperature indicator sticks, available from welding supply stores, to be sure the cylinder head is heated to the proper tem- perature. Apply a light coating of Prussian Blue t o each valve seat.

Tap the valve against the valve seat several times without rotating the valve, t o check for proper valve seat contact. Be careful not to grind the seat more than neces- sary. Install the valve spring seats. Install new stem seals. Lubricate the valve stem sliding surface with molyb- denum oil solution. Install the inner and outer valve springs with the tightly wound coils facing the combustion chamber.

Apply oil to the cylinder head nut threads and seating surfaces. Install the cylinder head nuts with the washers and tighten them in a crisscross pattern in 2 or 3 steps. Note the position of the large washer.

Install the camshaft onto the cylinder head through cam sprocket. Install the cam sprocket onto the camshaft flange securely.

Turn the tensioner shaft clockwise with the stopper tool to retract the tensioner, then insert the stopper fully to hold the tensioner in the fully retracted posi- tion.

Install the rocker arm shafts with new sealing washers. Apply locking agent to the 3 threads of the rocker arm shafts and tighten the shafts. Clean the mating surfaces of the cylinder head and head cover. Pour engine oil into the oil pocket in the cylinder head. Rotate the crankshaft counterclockwise and align the The crankshaff "T" Install the cylinder head cover onto the cylinder head. Install the 8 mm and 6 rnrn cylinder head cover bolts and tighten them in a crisscross pattern i n 2 or 3 steps.

Page MEMO Page 44 N m 4. Page 8. Take care not to damage the cylinder wall and piston. Do not damage mating surfaces by using a screwdriver when removing the cylinder. Camshaft lubricating oil is fed through the oil passage in the cylinder. Remove the 6 mm cylinder bolts. Remove the cam chain guide front.

Remove the four 10 mm cylinder bolts and washers. Do not strike the Remove the cylinder. Clean carbon deposits from the piston. Page Check the top of the cylinder for warpage with a straight edge and feeler gauge across the studs and bolt holes as shown.

The rings should be able t o move in their grooves without catching. Page Measure piston pin hole I. Take the maximum reading to determine the I. Measure the piston pin at three points. To install the oil ring, install the spacer first, then install the side rails. Do not align the piston pin clip end gap with the piston cutout. Page Apply oil to the cylinder wall, piston and piston ring outer surfaces. Route the cam chain through the cylinder and install the cylinder over the piston while compressing the piston rings with your fingers.

Page N m Page 9. Engine oil viscosity and level and the use of oil additives have an effect on clutch operation. Remove the two bolts and clutch cable holder, and disconnect the clutch cable from the clutch lifter arm.

Remove the bolts, oil pipes O-rings and dowel pins from the right crankcase cover. Remove the O-ring and oil pump driven sprocket from the oil pump. Check the lifter arm spindle for wear or damage. Check the return spring for fatigue or damage. Remove the bolts and springs. Remove the pressure plate and lifter piece.

Remove the clutch discs and plates. Unstake the clutch center lock nut. Be carefulnor to damage the threads. Page Remove the lock washer, plain washer and clutch center. Remove the thrust washer, clutch outer and clutch outer guide. The bearing should turn smoothly and quietly. Also check that the outer race of the bearing fits tightly in the pressure plate.

Replace the Check the plate warpage o n a surface plate using a clutchdiscsand Page Measure the mainshaft O. Install the clutch outer and thrust washer. Install the clutch center and plain washer. Apply oil to the threads and seating surface of a new clutch center lock nut and install it onto the mainshaft. Hold the clutch center with the special tool and tighten the lock nut. Page Apply oil to the clutch lifter piece whole surface and lifter bearing. Install the clutch lifter piece and pressure plate.

Install the clutch springs and bolts. Tighten the bolts in a crisscross pattern in several steps. Install the right crankcase cover page Page Apply oil to the primary drive gear nut threads and seating surface. Install the washer and primary drive gear nut. Remove the oil pump page Install the clutch outer onto the mainshaft. Install the special tool between the primary drive and driven gears as shown and tighten the primary drive gear nut.

Page Flywheel bolt Apply locking agent to the threads. Remove the gasket and dowel pins. Remove the spacer, starter idle gear and shaft from the left crankcase cover. Remove the seatlrear fender page Disconnect the alternator connectors. Page Remove the nut, seven bolts and the left crankcase cover.

Remove the starter reduction gear shaft and gear. Remove the two ignition pulse generator bolts and wire clamp. Coat new O-ring with oil and install it into the starter motor groove.. Install the dowel pins and a new gasket Install the left crankcase cover, being careful not to pinch the neutral switch wire.

Page Route the alternator wire properly page Connect the alternator connectors. Install the seatlrear fender page Install the starter idle gear shaft, gear and spacer in the left crankcase cover. Install the dowel pins and new gasket. Install the starter idle gear cover and tighten the four bolts securely. Page Starter Clutch Remove the flywheel using the special tool. Remove the starter driven gear while turning it coun- terclockwise.

Check the starter clutch outer and sprag clutch for abnormal wear or damage. Camshaft sprocket Inspect the teeth of each camshaft sprocket for wear or damage. If they are worn or damaged, replace the camshaft and cam chain as a set. Automatic decompression Move the automatic decompression weight by hand to inspect if it is operating smoothly. If the automatic decompression weight does not operate smoothly, replace it with a new one.

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