BOOK MARKED CHAPTERS INCLUDE:

Honda 1999-2002 Honda TRX-400EX general information.

This chapter includes important service rules, model identification, specifications, tools, lubrication and seal points, cable and harness routing, emission control systems and emission control information label. Below are just a small sample of some specification data table charts included in this manual:

1. DIMENSIONS (overall length, overall width, height, wheelbase, curb weight, dry weight, maximum weight capacity and much more).
2. FRAME (frame type, front suspension, front wheel travel, rear wheel travel, front tire size, camber angle, fuel tank capacity and much more).
3. ENGINE (cylinder arrangement, bore and stroke, engine displacement, compression ratio, valve train, intake valve, exhaust valves, lubrication system, oil pump type, cooling system, air filtration, crankshaft type, engine dry weight and more).
4. CARBURETOR (carburetor type, throttle bore).
5. DRIVE TRAIN (clutch system, clutch operation system, transmission, primary reduction, gear ratio, Gear shaft pattern and more).
6. Electrical (ignition system, starting system, charging system, regulator/rectifier, lighting system and more).
7. LUBRICATION (engine oil capacity, recommended engine oil type, viscosity, api service classifications, equivalent motor oil, oil pump, tip clearance, body clearance and more).
8. FUEL SYSTEM (carb identification number, main jet, slow jet, pilot screw opening, float level, jet needle, idlw speed, throttle lever free play and much more).
9. CYLINDER HEAD & VALVE (cylinder compression at 800 rpm, valve clearance, valve, valve guide, stem-to-stem clearance, valve spring free length, inner valve spring, outer valve spring, rocker arm, rocker arm I.D., cylinder head warpage and more).
10. CYLINDER (I.D., out of round, taper, warpage, piston, piston pin, piston ring, piston pin bore, piston-to-piston pin clearance, piston ring-to-ring clearance, cylinder to piston clearance, connecting rod to piston pin clearance, camshaft, cam follower, came lobe height and much more.
11. CLUTCH (change clutch, spring free length, disc thickness, plate warpage, clutch outer guide O.D., clutch outer guide boss I.D., centrifugal clutch, weight lining thickness, clutch spring height, drum bushing and more).
12. IGNITION SYSTEM (spark plugs, spark plug gap, spark plug standard and for cold climate, ignition coil peak voltage, peak pulse generator voltage, alternator exciter coil peak voltage, ignition timing F"mark and more).

Honda Fourtrax 1999-2002 Honda TR400-EX frame, body panels, exhaust system.

Topics covered in this chapter include: service information, troubleshooting, seat, fuel tank cover, side cover, front fender, rear fender, front carry pipe, rear carry pipe, handlebar cover, mud guards, mud guard strays, foot peg, skid plate, fuel tank, heat protector, exhaust system and more.

Honda 1999-2002 Honda TR400 EX maintenance.

This maintenance chapter includes: service information, maintenance schedule chart, fuel line, throttle operation, carburetor choke, air cleaner, air cleaner housing drain tube, spark plug, valve clearance, engine oil, engine oil strainer screen, engine oil centrifugal filter, idle speed, rear final gear case oil, brake fluid, brake shoes wear, brake pads, brake system, reverse lock system, skid plate and engine guard, clutch system, spark arrester, nut bolds and fasteners, wheels and tires, steering shaft holder bearing, steering system and more.

1999-2002 Honda TRX 400EX lubrication system.

The lubrication data in this chapter includes service information, troubleshooting, oil pump, oil cooler with high quality pictures, picture illustrations, picture diagrams and specification charts and is also contained in all chapters in this manual.

1999, 2002 Honda TR400EX fuel system.

Stop spending hundreds of dollars at your local Honda Certified Technician repair shop and do-it-yourself (DIY) and save money. Here is some of the topics covered in this fuel system chapter: air cleaner housing, carburetor removal, carburetor disassemble, carb assembly, carb installation, pilot screw adjustment, high altitude adjustment and more.

1999-2002 Honda TRX-400-EX engine removal, installation.

This engine removal and installation chapter includes a complete picture diagram and illustration of the disassembly and assembly of your Honda engine combined with all table charts, specifications, troubleshooting and engine removal and installation procedures.

1999-2002 Honda TR400EX cylinder head, valve.

Topic covered in the cylinder head and valve chapter include: cylinder compression, cylinder head cover, cylinder head removal, disassembly, inspection, valve guide replacement, valve seat inspection, refacing, cylinder head assembly, installation and more.

Other chapters in this Honda 1999, 2000, 2001 & 2002 TRX400 EX Service Manual includes:

Cylinder, piston, camshaft
Clutch
Gearshift linkage
Alternator, starter clutch
Crankshaft, transmission
Front wheel, suspension, steering
Rear wheel, brake, suspension
Hydraulic disc brake
Rear driving mechanism
Battery, charging system
Ignition system
Electric starter
Lights, switches
Wiring diagram

Troubleshooting

This TRX ATV Owners Service Manual Troubleshooting chapter includes a systematic approach to problems associated with the TRX EX explaining procedures to fixing specific malfunctions with questions and answers to test and identify the exact problem. Stop having ask your local Honda repair technician question like why wont the engine start? where do I check for fuel pressure? how do I test the starter, what is causing the spark plugs to be fouled?

1. Engine does not start.
2. Engine has difficulty starting.
3. Engine is lacking power.
4. Poor performance at low and idle speed.
5. Performance at high speed
6. Poor Handling.
7. Weak or no spark.
8. Low Compression
9. Engine starts but stops.
10. Wheel does not spin freely.
11. Engine speed does not increase.
12. Fouled or discolored spark plugs.
13. Engine knocks (strange knocking or tapping sound).
14. Weak or Intermittent spark.
15. Vehicle pulls to one side

Special Highlights of chapters include: Service Information, Troubleshooting, Part or Parts Removal, Di