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  Honda TRX400, TRX400EX Fourtrax, Sportrax ATV Repair Manual 1999-2007
  Kawasaki Ninja ZX900, ZX1000, ZX1100 Repair Manual 1984-2001
 
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Product Code: CL-M454-4

 
 
This repair manual covers Honda TRX400EX Fourtrax (TRX400) 1999-2000 and TRX400EX Sportrax 2001-2007.

Table of Contents

QUICK REFERENCE DATA

CHAPTER ONE: GENERAL INFORMATION
Manual organization | Basic service methods | Warnings, cautions and notes | Safety | Serial numbers | Fasterners | Shop supplies | Basic tools | Precision measuring tools | Storage

CHAPTER TWO: TROUBLESHOOTING
Operating requirements | Starting the engine | Engine spark test | Engine performance | Electrical testing | Engine starting system | Engine noise | Vehicle noise | Engine leakdown test | Clutch | Gear shift linkage and transmission | Brakes | Steering and handling

CHAPTER THREE: LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride checklist | Engine break-in | Service intervals | Tires and wheels | Battery | Lubricants | Periodic lubrication | Periodic maintenance | Engine tune-up

CHAPTER FOUR: ENGINE TOP END
Cleanliness | Cylinder head cover | Camshaft, cam chain sprocket, and tensioner | Decompressor | Cylinder head | Valves and valve components | Cylinder | Piston and piston rings | Break-in

CHAPTER FIVE: ENGINE LOWER END
Shop cleanliness | Drive sprocket | Cam chain, sprocket and guides | Engine | Crankcase (1999-2004 models) | Crankcase seal and bearing replacement | Crankshaft | Engine break-in

CHAPTER SIX: CLUTCH, GEARSHIFT LINKAGE AND LUBRICATION SYSTEM
Right crankcase (1999-2004 models) | Clutch | Gearshift linkage | Primary drive gear | Oil pump | Crankcase oil strainer | Oil cooler | Oil tank

CHAPTER SEVEN: TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission operation | Service notes | Mainshaft | Countershaft (1999-2004 models) | Transmission inspection | Shift drum and forks | Gearshift spindle and plate

CHAPTER EIGHT: FUEL AND EXHAUST SYSTEMS
Air cleaner | Carburetor | Carburetor inspection and repair | Carburetor adjustments | Throttle control and cable | Exhaust pipe and muffler

CHAPTER NINE: ELECTRICAL SYSTEM
Basic electrical system operating | Left crankcase cover and stator | Flywheel | Starter clutch | Starter motor | Starting system switches | Handlebar switch unit | Ignition system | Fuse | Charging system | Lights

CHAPTER TEN: FRONT SUSPENSION AND STEERING
Front wheel | Front hub | Tie rods | Steering knuckle | Control arms | Shock absorbers | Steering shaft | Handlebar | Tires and wheels

CHAPTER ELEVEN: REAR SUSPENSION
Rear wheel | Rear hub | Rear axle | Rear axle bearing holder | Driven sprocket | Drive chain | Shock absorber | Rear suspension adjustment | Shock linkage | Swing arm

CHAPTER TWELVE: BRAKES
Disc brake fundamentals | Front brake pads | Front brake caliper | Front master cylinder | Rear brake pads | Rear brake caliper | Rear master cylinder | Brake pedal | Brake discs

CHAPTER THIRTEEN: BODY
Seat and rear fender | Upper cover (1999-2004 models) | Side covers | Front fender | Handlebar cover | Fuel tank | Fuel tank heat protector | Footpegs and mudguard | Tool box

SUPPLEMENT: 2005-ON MODEL SERVICE INFORMATION
Gear shift linkage and transmission | Periodic maintenance | Engine | Right crankcase cover | Reverse stopper plate | Transmission operation | Mainshaft | Countershaft | Reverse idle gear and shaft | Reverse switch | Taillight | Side covers | Upper headlight cover | Lower headlight cover | Front fenders

COLOR WIRING DIAGRAMS

Clymer ATV repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.
PRODUCT DETAILS:
  • Publisher: Clymer Manuals ó 2008
  • Author: Jay Bogart, Ron Wright - Photography
  • Binding: Paperback ó 7 x 10 inches
  • Pages: 324 ó Hundreds of b&w photos and illustrations
  • ISBN: 9781599692517

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