Honda Trx400 EX 2006 Service Repair Manual

A Few Words About Safety Service Information The 5efV1ce and repair information contained In this manual IS Intended for use by qualified, professional technicians. Attempting service Of repairs WIthout the proper training tools. and eqUIpment could cause Infury to you or others. It could also damage the vehicle Of create an unsafe condition This manual descnbes the proper methods and procedures lor performing servICe mamtenance, and repa.rs Some procedures require the use 01 specially deSigned lOOIs and dedicated equipment Any person whO intends to use a replacement part, servICe procedure or a loollhat is nol recommended by Hooda, must determine the nsks to their personal safety and the safe operatiOn of the vehicle If you need to replace a part use genuine Honda parts with lhe correct pari number or an equivalent part We strongly recommend thai you do not use repiacement parts of infenor qualrty. For Your Customer's Safety Proper service and maintenance are essential to the customer's safety and the reliability 01 the vehicle Any error or overSight while servicing a vehicle can result in faulty operation, damage to the vehicle, or injUry to others. For Your Safety Because thiS manual IS Intended lor the professional selVlce technician we do not provide warnings about many baSIC shop safety practices (e.g. Hot parts-wear gloves). II you have nol received shop safety training or do I"IOt JeeI oonloonl about your knowledge of safe servicing practice we recommended thaI you do nol attempt to perform the procedures described ., this manual. Some of the most Important general sen/Ice safety precautIOns are given below. However, we cannot warn you of fNefY conceivable hazard that can anse In performing sen/ICe and repair procedures Only you can decide whether or not you should perform a given task. Important Safety Precautions AWARNING Improper service or repaJrs can create an unsafe condition that can cause your customer or others to be seriously hurt or killed, Follow the procedures and precavtK)(ls in thiS manual and other selVlCe matenals carefully. AWARNING Failure 10 properly follow Instructions and precautions can cause you to be senously hurt or klled Follow the procedures and precautiOns In 1t'IIS manual carefully. Make sure you have a clear understanding of all baSIC shop safety practJces and that you are weam"IQ appropriate clothing and USing safety eqUipment, When performing any service task. be eSpE!C1ally careful 01 the follOWing' • Read all of the Instructions belore you begin. and make sure you have the tools, the replacement or repair parIS, and the skills reqUired to perform the tasks safety and completely. • Protect your eyes by usmg proper salety glasses, goggles or lace shields any time you hammer. dnn. grind, pry or work around pressurized air or liquids, and springs or other stored-energy componeols If there IS any doubt, pul on eye proteCllon. • Use other protective wear wheo necessary. for example gloves or salety shoes. Handling hot or sharp parts can cause severe burns or cuts. Belore you grab somethmg lhat looks like it can hurt you stop and put on gloves • Protect yourself and others whenever you have the vehicle up In the air Any time you lift the vehicle, enher with a hoist or a jack. make sure that It is always securely supported. Use jack stands. Make sure !he engine IS off helore you begin any serviclng procedures, unless the Inslruction tells you to do othefWIse This win help eliminate several potential hazards: • Carbon monOXIde poiSOning 'rom engine exhaust Be sure there is adequate venlliation whenever you run the engine. • Burns from hot parIs or coolant. Let the engine and exhaust system cool belere working In those areas • InjUry from moving pans. If the Instl1.JCOOn tells you to run the engine. be sure your hands. fingers and clothing are out ollhe way. Gasoline vapors and hydrogeo gases from battenes are explOSive. To reduce the possibility 01 a lire or explOSion, be careful when working around gasoline or batter;es • Use only a nonflammable solvent, not gasolme. to clean parts. • Never dram or Siore gasoline in an open container • Keep all Cigarettes. sparks and names away Irom the battery and ailluel'reiated parts . •

HOW TO USE THIS MANUAL This servICe manual dllSCflOOs the service procadures klf !he TAX400EX Follow the Maintenance Schedule (Section 4) recommendations \0 ensure thai the vehicle is in pa~k optIrallng oorditron and the emlssioo levels are within the slafldards set by the U,S. EnvIroomenlal Protection AgencY (EPA) and Cali lorma Air Resources Board (CARS) Perfon;niog the first Sd1eduled maintenaf10e is very importanl II compensates kif the ;nilial wear lhat occurs during tile break·1n period. Sections 1 and 4 aWy to tho whole vehtde SactKll1 3 lIIUS\rn,8S procedures for removaVinSlal!a\lon of components that may be reqUIred to perform S8fV1Ge dascrlbed In the IoIlow.og sectlOtlS. Sections 5 through 19 deSCribe parts o l lllll vehiCle', groupo:!d sccordll"9 10 \oCa.tW)n. Fmc! the section you warn on this page. then Mn to the table of contents on the fifSI page altha section Most sections sl art wtlh an assembly or system 1 II1I51ra6oo, service IntJrma\lon afld trwbleshoolmg lor Ihe sectlOfl The subooquent pages give detalilld procedure. I!)IOU are not IamHiar with rhos vehicle, read Techrucal Fealure lfl 5edion 2. It )IOU don1 knQw thl! source ot tha trouble, go to se<:tion 21 Troubleshooting Your safety. aoo the safely of others. as very Imponan!. To help you make Inbl'lned deasione we have pl'OYlded safety messages and OItIer Infofmallon throughout \tIlS manual. 01 course, it Is 001 pl8CIical or possible 10 warn you aboul all th(l ha~ards associaled wiItI serviCIng tIllS vehocla 'Ibu must use your 0WI'1 good Judgement You wi" lind Hnp<l(tant safety InlormabOn ,n a variety 01 forms including: • Sa\Qty Labels - on tho vehtclo • safety MtlS5aIl"'S - precWed by a safety alart symbol i and one 01 !hroo signal words. DANGER. WARNING. or CAUTION. These SlgNIt words mean: "'-dna; ;1 ;:RTV:;I~ :n·IK~LL!Oi,:,U::~OUSLY You CAN De KILLED or SERIOUSLY HURT m'i1;luw, l tI ,I you donllollow instrucOOns. mijijU.iU ~~~S~ HURT ~ you don·t follow • Instructions - how to sern;e thiS ~6'hicle correctly and salely. As you read ItIIS manual. you WIll flna lnlomlallOfl !ha! is preceded by a [I()1'JC[l symbol The PUfpoie 01 this message is 10 htllp proven! damage 10 your Y8I1lCla, oltler property, Or tho environment. w ;!; C> z w -' '" () a: t; w -' w CONTENTS GENERAL INFORMATION TECHNICAL FEATURE MAINTENANCE LUBRICATION SYSTEM FUEL SYSTEM ENGINE REMOVAUINSTALLATION CYLINDER HEADNALVE CVLlNDERIPISTON CLUTCH/GEARSHIFT LINKAGE ALTERNATOR/STARTER CLUTCH CRANKCASE/TRANSMISSION/CRANKSHAFT FRONT WHEEUSUSPENSIONISTEERING REAR WHEEUSUSPENSION HYDRAULIC DISC BRAKE BATTERY/CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER LlGHTSlSWITCHES WIRING DIAGRAM TROUBLESHOOTING INDEX

SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the texl without the use of the symbols. I!!I Replace the part(s) with new one(s) before assembly. ---"l Use the recommended engine oil, unless otherwise specified. 7J Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1: 1). • .s.;m;~ Use mUlti-purpose grease (lithium based mUlti-purpose grease NLGI #2 or equivalent). Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent). ~ Example: Molykote® BA -2 plus manufactured by Dow Corning U.SA Multi-purpose M-2 manufactured by Milsubishi Oil, Japan Use molybdenum disulfi de paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent). Example: Molykote® G'n Paste manufactured by Dow Corning U.S.A. AID Honda Moly 60 (U.S.A. only) Roeol ASP manufactured by Roeol Limited, U.K. Roeol Paste manufactured by Sumico Lubricant, Japan ..-'iSWI Use silicone grease. 0,. Apply a locking agent. Use a medium strength locking agent unless othelWise specified. - JGJIl Apply sealant. I Use DOT 4 brake fluid. Use the recommended brake fluid unless othelWise specified. GIl Use fork or suspension fluid.

1. GENERAL INFORMATION SERVICE RULES ··· .... ····································· 1-2 MODEL IDENTIFiCATION ······························ 1-2 GENERAL SPECiFiCATIONS ············· ·· ······· ·· · 1-5 LUBRICATION SYSTEM SPECiFiCATIONS··········································· 1-7 FUEL SYSTEM SPECiFiCATIONS················· 1-7 CYLINDER HEAD/VALVE SPECiFiCATIONS··········································· 1-7 CYLINDER/ PISTON SPECIFICATIONS ········· 1-8 CLUTCH/ GEARSHIFT LINKAGE SPECiFiCATIONS··········································· 1-8 ALTERNATOR /STARTER CLUTCH SPECiFiCATIONS········································ ... 1-8 CRANKCASE/ TRANSMISSION/ CRANKSHAFT SPECiFiCATIONS··········································· 1-9 FRONT WHEEL /S USPENSION/STEERING SPECiFiCATIONS··········································· 1-9 REAR WHEEl/SUSPENSION SPECiFiCATIONS···· ······································1-10 HYDRAULIC DISC BRAKE SPECiFiCATIONS········ ··· ·· ······· ·· ·· ··· ·· ····· ··· ·· ··· 1-10 BATTERY/ CHARGING SYSTEM SPECiFiCATIONS·········································· 1·10 IGNITION SYSTEM SPECIFICATIONS ········ 1-10 ELECTRIC STARTER SPECIFICATIONS ······ 1-10 LIGHTS/SWITCHES SPECIFICATIONS ······· 1-11 STANDARD TORQUE VALUES ··················· 1-12 ENGINE & FRAME TQRQUE VALUES ··· ····· 1-12 LUBRICATION & SEAL POINTS ··········· ·· ····· 1-16 CABLE & HARNESS ROUTING ··················· 1-18 EMISSION CONTROL SYSTEMS ················ 1-28 1-1

GENERAL INFORMATION SERVICE RULES 1. Use genuine Honda or Honda-recommended pans and lubricants or their equivalents. Pans that do not meet Honda's design specifications may cause damage to the vehicle. 2. Use the special tools designed for this product to avoid damage end incorrect assembl y. 3. Use only metric tools when servicing the vehicle. Metric bolts, nuts and screws are not interchangeable with English fasteners . 4. Install new gaskets, O-rings, cotter pins. and lock plates when reassembling. 5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless 8 particular sequence is specified. 6. Clean parts in cleaning solvenl upon disassembly. Lubricate any sliding surfaces before reassembly. 7. After reassembly, check all parts for proper installation and operation. 8. Route all electrical wires as shown in the Cable and Harness Routing (page 1-18). MODEL IDENTIFICATION '05 - ' 07 sho wn : DESTINATION CODES Throughoullhis manual. the following are used to identify individual types for each region. DESTINATION CODE U.S.A. Canada REG ION A eM u Australia (New Zealand, European Direct Sales) ---'---- 1-2

The Vehicle Identification Number (VI N) is stamped on the front of the frame. The engine serial number is stamped on the left side of the crankcase. The name plate (U.S.A. and U type) or Safety Certification Label (Ca nada) is attached on the front frame pipe. GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBER ~~t ~ ENGINE SERIAL NUMBER \\ \ Canada: "--.,.,,,,~ S 'i AFETY CERTIFICATION LABEL 1-3

GENERAL INFORMATION The carburetor identification number is stamped on the left side of the carburetor body. The Vehicle Emission Information Label is attached on the right front frame pipe (U.S.A. only). CARBURETOR IDENTIFICATION NUMBER The color label is attached on the left side of the frame under the seat. ,------------------, When ordering color coded parts, always specify the designated color code. COLOR LABEL 1-4

GENERAL INFORMATION GENERAL SPECIFICATIONS I DIMENSIONS ITEM Overali length Overall width Overall height Wheelbase Front tread Rear tread Seat height Footpeg height Ground clearance Dry weight Curb weight SPECIFICATIONS 1,822 mm ( 71.7 in) 1. 155mm (45.5 inJ 1,111 mm (43 .7 in) 1.217 mm (47.9 in) 920 mm (36.2 in) 900 mm (35.4 in) 80B mm (3 1.8 in) 348 mm (13.7in) 105 mm (4.1 in) 176 kg (388lbs) 184 kg (406lbs) r FRAME __ --I-I M2C'x :=imum weight capacity Frame type __ -,-- ,110 kg (243 Ibs) Double cradle Double wish -bone 209 mm (8.2 in) Double tube Swingarm ENGINE Front suspensi on Front wheellravel Front damper Rear suspension Rear wheellravel Rea r damper Front tire size Rear lire size Front rim size Rear rim size Front lire brand Rear tire brand Front brake Rear brake Caster angle Trail length Camber angle Fuel tank capacity Fuel tank reserve capacity Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train Intake valve opens at 1 mm (0.04 in) 11ft Intake valve doses al 1 mm (0.04 in) lift Exhaust valve opens at 1 mm (0.04 in) lift EKhaust valve closes at , mm (0.04 in) lift lubrication system Oil pump type Cooling system Air filtration 230 mm (9.1 in ) Single tube AT22 x 7-10 * * AT20 x 10-9 .. * IOx5.5AT 9x8.0AT MIR 101 (Ohtsu) MIR 501 (Ohtsu) Hydraulic disc x 2 Hydraulic disc r 32 mm (1 .3 in) _ 0.8 D 10 liters (2.6 US gal, 2.2 Imp gal) 1.6 liters (0.42 US gal, 0.35 Imp gal) Single cylinder. transversely installed 85.0 x 70.0 mm (3.35 x 2.76 in) 397 cm 3 (24 .2 cu-!n) 9.1 : 1 Chain driven OHC with rocker arm 5° BTDC 40° ABDC 40° BBDC 5<> ATDC Forced pressure (dry sump) Trochoid Air cooled Oiled urethane foam CARBURETOR Engine dry weight Carburetor type _ __ ,,4"'2."'5,, ' ''''9 (93.7 .lcb~'J~ _ __ _ Piston valve ~ _______ LT~h ~, -",onle bore 38 mm (1.5 in) - 1-5

GENERAL INFORMATION r---oruVE TRAIN ITEM $PECIACATIONS I Clutch system Multi -plate, wet Clutctl operation system Cable operated Transmission Constant mesh, 5-speed ... Reverse Primary reduction 2.826 (23/65) Final reduction 2.785 (1 4/39) Gear ratio ,,, 2.727 (11/30) 'od 1.789 (1 9134) 3,d 1.363 (22130) 4th 1. 080 (25127) 5th 0.925 (27/25) Reverse 2.428 (14121 x 21134) I ELECTRICAL Gearshift panern Left fool operated rel urn system, R-l-N-2-3-4-5 Ignition syst em AC-CDI Starting system Electric starter motor Charging system Single phase outpu t alternator Regulator/rectifier Single phase full-wave rectification , lighting system Banery - 1-6

Honda Trx400 EX 2006 Service Repair Manual

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