INSTANT DOWNLOAD 2003 Honda TRX400 TRX400EX, TRX400FW (TRX-400-EX-FW) Sportrax, Fourtrax Foreman Service Manual


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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.

Cylinder head cover
• Thoroughly wipe off oil from the fitting surfaces of the cylinder head and cover.
• Apply bond to the end caps of the cylinder head cover gasket as shown in the figure.  : Sealant 99000–31140

! CAUTION Use a new gasket to prevent oil leakage.

• Apply engine oil to both sides of the washer and cushion.

! CAUTION Use new washers and cushion to prevent oil leakage.

• Tighten the cylinder head cover bolts in diagonal stages to the specified torque.

Tightening torque
Cylinder head cover bolt: 14 N·m (1.4 kgf-m, 10.0 lb-ft)

Valve Clearance Inspection and Adjustment
Refer to “Valve Clearance Inspection and Adjustment in Section 0B (Page 0B-5)”.

Camshaft Inspection
Refer to “Engine Top Side Disassembly (Page 1D-17)” and “Engine Top Side Assembly (Page 1D-20)”.

! CAUTION Do not attempt to disassemble the camshaft/ automatic decompression assembly. It is not serviceable.

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. Measure the cam height “a” with a micrometer. Replace a camshaft if the cams are worn to the service limit.

Special tool

: 09900–20202 (Micrometer (1/100 mm, 25 – 50 mm))
Cam height “a”
Service limit (IN.): 35.890 mm (1.4130 in)
Service limit (EX.): 34.620 mm (1.3630 in)

Camshaft journal wear
Inspect the camshaft journal wear in the following procedures:

1) Determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place.
2) Use the plastigauge to read the clearance at the widest portion, which is specified as follows.

Special tool
(A): 09900–22301 (Plastigauge (0.025 – 0.076 mm))
(B): 09900–22302 (Plastigauge (0.051 – 0.152 mm))

3) Install each camshaft journal holder to its original position. Refer to “Engine Top Side Assembly (Page 1D-20)”.
4) Tighten the camshaft journal holder bolts evenly and in diagonally to the specified torque. Refer to “Engine Top Side Assembly (Page 1D-20)”.

NOTE Do not rotate the camshafts with the plastigauge in place.

Tightening torque
Camshaft journal holder bolt (a): 10 N·m (1.0 kgf-m, 7.0 lb-ft)

5) Remove the camshaft journal holders and measure the width of the compressed plastigauge using the envelope scale.
6) This measurement should be taken at the widest part of the compressed plastic gauge.

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