INSTANT DOWNLOAD 2000 Honda TRX400, TRX400FW, TRX400EX, TRX-400-EX-FW Sportrax, Fourtrax Foreman Service Repair Manual


 

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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.


Engine Engine Mechanical
Diagnostic Information and Procedures
Engine Mechanical Symptom Diagnosis
Refer to “Engine Symptom Diagnosis in Section 1A (Page 1A-7)”.

Compression Pressure Check

The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic maintenance records kept at your dealership should include compression readings for each maintenance service.

• Before checking the engine for compression pressure, make sure that the cylinder head nuts are tightened to the specified torque values and the valves are properly adjusted.
• Make sure that the battery is in fullycharged condition.

1) Warm up the engine.
2) Remove the fuel tank lower cover. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”.
3) Remove the spark plug. Refer to “Spark Plug Cap and Spark Plug Removal and Installation in Section 1H (Page 1H-4)”.
4) Install the compression gauge and adaptor in the spark plug hole. Make sure that the connection is tight.

Special tool
(A): 09915–64512 (Compression gauge)
(B): 09915–63311 (Compression gauge attachment)

5) Disconnect the fuel pump lead wire coupler (1).
6) Remove the ignition switch and connect the ignition switch coupler. Refer to “Ignition Switch Removal and Installation in Section 1H (Page 1H-7)”.
7) Shift the transmission to the neutral, turn the ignition switch ON and grasp the clutch lever.
8) Keep the throttle lever in the fully-opened position.
9) Press the starter button and crank the engine for a few seconds. Record the maximum gauge reading as the cylinder compression. Compression pressure specification Low compression pressure can indicate any of the following conditions:

• Excessively worn cylinder wall
• Worn piston or piston rings
• Piston rings stuck in grooves
• Poor valve seating
• Ruptured or otherwise defective cylinder head gasket

10) After checking the compression pressure, reinstall the removed parts.

Repair Instructions
Engine Components Removable with the Engine in Place. Engine components which can be removed while the engine is installed on the frame are as follows. For the installing and removing procedures, refer to respective paragraphs describing each component.

 

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