INSTANT DOWNLOAD 1999 Honda TRX400, TRX400FW, TRX400EX (TRX-400-FW/EX) Sportrax, Fourtrax Foreman Service Manual


1999 Honda TRX 400 Service Manuals

 

 Download Manuals Below

Service Manual >1995-2003 Foreman TRX400FW TRX 400

Service Manual >1999-2002 TRX 400EX, TRX400 EX

Service Manual >2004-2005 Rancher TRX400FA TRX400FGA TRX400

Service Manual >2006-2007 Rancher TRX400FA, TRX400FGA, TRX400

Service Manual >2005-2009 TRX 400EX, TRX 400X


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This manual contains an introductory description on the Honda TRX400, 400 and procedures for its inspection/service and overhaul of its main components. Other information considered as generally known is not included.

Read the GENERAL INFORMATION section to familiarize yourself with the vehicle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service.

This manual will help you know the vehicle better so that you can assure yourself  of fast and reliable service.

* This manual has been prepared on the basis of the latest specifications at the time of publication. If modifications have been made since then, differences may exist between the content of this manual and the actual vehicle.

* Illustrations in this manual are used to show the basic principles of operation and work procedures.

* This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing vehicles. If you do not have the proper knowledge and tools, ask your authorized dealer to help you.


Air Cleaner Element Removal and Installation
Removal

1) Remove the seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-4)”.
2) Remove the air cleaner box cover (1).
3) Remove the holder (2) and air cleaner element (3).
4) Separate the polyurethane foam element (4) from the element frame (5).

Installation
Installation in the reverse order of removal.

Air Cleaner Element Cleaning
Refer to “Air Cleaner Element Cleaning in Section 0B (Page 0B-4)”.

Air Cleaner Box Removal and Installation

Removal
1) Remove the seat and fuel tank cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-4)”.
2) Remove the air cleaner duct (1) and disconnect the PCV (breather) hose (2).

3) Loosen the air cleaner box clamp screw (3).
4) Disconnect the IAT sensor coupler (4).
5) Remove the air cleaner box (5) by removing the air cleaner box mounting bolts.

Installation
Install the air cleaner box in the reverse order ofnremoval. Pay attention to the following points:

Tighten the air cleaner box mounting bolts to the specified torque.
Tightening torque Air cleaner box mounting bolt (a): 10 N·m (1.0 kgfm, 7.0 lb-ft)

Throttle Cable Removal and Installation

Removal
1) Remove the fuel tank and fuel tank lower cover. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”.
2) Remove the throttle cable as shown in the cable routing diagram. Refer to “Hose and Cable Routing Diagram in Section 4A (Page 4A-3)”.

Installation

Install the throttle cable in the reverse order of removal. Pay attention to the following points:

• Install the throttle cable as shown in the cable routing diagram. Refer to “Hose and Cable Routing Diagram in Section 4A (Page 4A-3)”.
• Check the throttle cable play and proper operation.

Refer to “Throttle Cable Play Inspection and Adjustment in Section 0B (Page 0B-10)”.

Throttle Cable Inspection
Check that the throttle lever move smoothly from full open to full close. If it does not move smoothly, lubricate the throttle cable.

Throttle Cable Play Inspection and Adjustment
Refer to “Throttle Cable Play Inspection and Adjustment in Section 0B (Page 0B-10)”.

Throttle Body Inspection
Refer to “Throttle Body Inspection in Section 0B (Page 0B-10)”.

Throttle Body Removal and Installation

Removal
1) Remove the front fender. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-

2) Remove the fuel tank lower cover. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”.
3) Remove the oil return tank. Refer to “Oil Return Tank Removal and Installation in Section 1B (Page 1B-2)”.
4) Disconnect the TP sensor lead wire coupler (1).

 

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