HOW TO USE THIS MANUAL This service manual deSCfiOOs the SllfVice TRX400FA/TRX-4OOFGA.
CONTENTS
procedures lor the
GENERAL INFORMATION
Follow !he Maimenance Schedule (Sectioo 4) recommendations 10 8I\SUta thaI the veOide Is in peaIt operating cond>tion and the emISSion kNels are wit!l,n!he slanOO.(lS set by !he Calilomlll Air Resources Board. PerIooning the first &eheduled maintenance Is very il\"flOf1llnl. COITIpIIflS8les!of the Initial wear thai occtJlS during Ihe bfellk-In pefiod .
TECHNICAL FEATURE
'I
MAINTENANCE
Sec:IIon$ 1 end 4 awtv 10 the whole vehicle. 5ecI1on 3 illl.$lrales ptocedures lor remtlY8V1ns1aJllllion 01 components thaI may be required 10 perform selVice described in the following sectioos. Section Slhrough 25 descOOe parts althe vehicle, grouped according 1o
""""'"
F~ the seclion you want on this page. on !he HISI page 01 the sactlon.
LUBRICATION SYSTEM FUEL SYSTEM
then turn 1o the table 01 contents
ENGINE REMOVALI1NSTALLATION
Most sectioos start with an assembly or system Hluslrallon. seMce Inlormatior! and troubleshooting lor the SOCOOn. The subsequent pag&s giYe deUliled procedure. II you are fIOIlamiliar WIth tlus vehicle, go 10 section 2 Technical Feature. ~ )IOU don1 know the soorcu or the trOUble. go 10 soolion 26
TroubIe5hootlng.
w
z az w
Your safely, and the salety 0/ oth8fs, Is very important. To heIp)lOU mak8 lntormed d9cisions we haY!! provided safety messages and other information throughout thIS manual, 04 OOUI'!)e, it is I"(lt pmctical or pOSSible to wern you about all the /laZarUs associated with sefVicing this vehicle.
CYLINDER/PISTON
CENTRIFUGAL CLUTCH ALTERNATOR/STARTER CLUTCH
SUB-TRANSMISSION/GEARSHIFT LINKAGE
You must LiSe your own good Judgement. You wiH lind Imporlant safi!1y InIormalion In a variety of IoIms
CRANKSHAFT/AUTOMATIC TRANSMISSION
lneIuding:
• Safety Labels
CYLINDER HEADNALVEICAMSHAFT
-00 the vehicle
It
• Safely Messages - preceded by 8 safety alert symbol sod one 01 tlwee sgnallYOrUs, DANGER , WARNING , or CAUTION These signal words mean:
FRONT WHEEUSUSPENSIDN/STEERING
fi.4i~[M;i ~RTV;;I~ :,,~~DI~~~SLY
IDb"Wt'!!f!:J
REAR WHEEUSUSPENSION
You CAN be KILLED or SERIOUSlY HURT Hyou don'l follow instructions.
tiM'm.U' :'~s~
HURT H you don"
BRAKE SYSTEM FRONT DRIVING MECHANISM
IoIIow
REAR DRIVING MECHANISM
• Instruo;t;o.ns _ how 10 service Itlis vehICle correctly and aaJely
At> )IOU read this manual, )IOU win find inlormatJon thai is preceded by a DlOt'iiXl symboi, The purpose 01 Itlis message is to help prevent damage to)'OUr vehicle, olh&r property, or the erwironm&n1 ,
BATTERY/CHARGING SYSTEM
. -' ~
~
W
IGNITION SYSTEM ELECTRIC STARTER L1GHTSlMETERSISWITCHES
-' W
SELECTABLE 4WD SYSTEM HONDAMATIC 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 text without the use of the symbols.
eI
Replace the partes) with new one(s) before assembly.
78
Use recommended engine oil, unless otherwise specified.
~ • UU;~
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1 : 1).
Use multi-purpose grease (lithium based multi-purpose grease NLGt #2 or equivalent) .
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent).
~
Example: Molykote® BR-2 plus manufactured by Dow Corning U.SA Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent). Example: Molykote® G-n Paste manufactured by Dow Corning U.S.A.
~
Honda Moly 60 (U.S.A. only) Aocol ASP manufactured by Aocol Limited, UK Aocol Paste manufactured by Sumico Lubricant. Japan
;1iSiiI
Use silicone grease.
ca
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
",-
Apply sealant.
I
..
Use DOT 4 brake fluid . Use the recommended brake ftuid unless otherwise specified.
Use Fork or Suspension Fluid .
1. GENERAL INFORMATION
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L
SERVICE RULES ............................................ 1-2
BRAKE SYSTEM SPECIFICATIONS·············1-10
MODELIDENTIFICATION····-·········_·········_····· 1-2
FRONT DRIVING MECHANISM SPECiFiCATIONS·········································· 1-11
GENERAL SPECIFICATIONS ·········_··············· 1-5 LUBRICATION S YSTEM SPECIFICATIONS · 1-7
REAR DRIVING MECHANISM SPECiFiCATIONS··········································1 -11
FUEL SYSTEM SPECiFiCATIONS ················· 1-7
BATTERY/ CHARGING SYSTEM SPECIFICATIONS·· ....................................... ·1-11
CYLINDER HEADIVALVE/ CAMSHAFT SPECiFiCATIONS ········································ ... 1-8
IGNITION SYSTEM SPECIFICATIONS ········ 1-11
CYLINDER/ PISTON SPECIFICATIONS ·--······ 1-8
ELECTRIC STARTER SPECIFICATIONS ······ 1-11
CENTRIFUGAL CLUTCH SPECIFICATIONS · 1-8
LIGHTS/ METERS/ SWITCHES SPECiFiCATiONS······························· ··········· 1-12
ALTERNATOR/ STARTER CLUTCH SPECIFICATIONS ·······_·········_·········_··············· 1-9
STANDARD TORQUE VALUES ··················· 1-13
SUB-TRANSMISSION SPECiFiCATIONS····· 1-9
ENGINE & FRAME TORQUE VALUES ········1-13
CRANKSHAFT/ AUTOMATIC TRANSMISSION SPECiFiCATIONS ··········································· 1-9
LUBRICATION & SEAL POINTS ·················· 1-19 CABLE & HARNESS ROUTING ··················· 1-24
FRONT WHEEl/SUSPENSION/ STEERING SPECIFICATIONS ····-···································· 1-10
EMISSION CONTROL SYSTEMS ··········· ····· 1-39
REAR WHEEL/ SUSPENSION SPECiFiCATIONS ········································· 1-10
EMISSION CONTROLINFORMA TlON LABEL (U .S .A. only) ····································· 1-40
1-1
GENERAL INFORMATION
SERVICE RULES 1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that don't meet Honda 's design specifications may cause damage to the vehicle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 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 plat es when reassembling. 5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified t orque diagonally in incremental steps unless a particular sequence is specified. 6. Clean parts in cleaning solvent 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 show in the Cable and Harness Routing (page 1¡24).
MODEL IDENTIFICATION '04 shown; Aft er '04 similar:
I
I
i 1-2
GENERAL INFORMATION The model identification label is located on the frame down tube.
The frame serial number is stamped on the front side of the frame.
The engine serial number is stamped on the left side of the rear crankcase.
The carburetor identification number is stamped on the leh side of the carburetor body.
1-3
GENERAL INFORMATION The color label is attached on the cross member of the frame under the seal. When ordering color coded parts, alwavs specify the designated
color code.
1-4
GENERAL INFORMATION
GENERAL SPECIFICATIONS ITEM DIMENSIONS
SPECIFICATIONS 2,031 mm (SO.O in) 1,114 mm (43.9 in) 1,157 mm (45.6 in) 1,246 mm (49. 1 in) 850 mm (33.5 in) 860 mm (33.9 in) 824 mm (32.4 in) 336 mm (13.2 in) 184 mm (7.2 in) 254 kg (560 Ibs) 265 kg (583 Ibs)
Overall length Overall width Overall height Wheelbase
Front tread Rear tread Seat height Footpeg height Ground clearance Dry weight
Curb weight '---..-"",,_ _ _--1_ Maximum weight capacity I FRAME Frame type Front suspension Front wheel travel
Front damper Rear suspension Rear wheet travel Rear damper Front tire size
Rear lire size Front rim sile Rear rim size Front tire brand Rear tire brand Front brake Rear brake
_ ______~2~2~O~kg{~5~lb~'I~-------Â Double cradle Double wishbone 150 mm (5.9 in) Double tube Tra iling 150 mm (5.9 in) Double tube AT24 x 8-12 AT24 x 10- 11 12x6.0AT 11 x 7.5 AT Bridgestone Sridgestone Hydraulic drum brake (Dual leading) Mechanical drum brake
**
**
4"
Caster angle Trail lengt h
Camber angle Fuel tank capacity h"'''''",-_ _ _--1---;. Fuel tank reserve capacity ENGINE Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train
Intake valve opens closes Exhaust valve opens closes
lubrication system Oil pump type Cooling system Ai r filtration h " "oo"""",,,,,_--1---:;. En g ine dry weight CARBURETOR Carburetor type L _ _ _ _ _ _-L Throttle bore
17 mm (0.7 in) 0.10 14.5 titers (3.83 US gal, 3.19 Imp gal) _ _ __ 1-:3~.~B~Ii~"~''''s:(lOO US gal, 0.84 Imp gal) Single cylinder, longitudinally installed 85 X 70 mm (3.35 X 2.76 in) 397 cm l (24.2 cu-i n) 9.1 : 1
OHV at 1 mm (0.04 in) lift at 1 mm (0.04 in) lift at 1 mm (0.04 in) lift at 1 mm (0.04 in) lift
7" STDC 42" ABDC 8" BBDC 39" ATDC Forced pressure (dry sump) Trochoid Air cooled Oiled urethane foam 51.7 kg (114.0 Ibs) Constant Vacuum (VE type) __________1-36 mm (1.4 in)'---___________
1-5
GENERAL INFORMATION ITEM DRIVE TRAIN
SPECIFICATIONS Centrifugal, wet
Clutch system
HQNOAMATIC (automatic; non-stage speed) with sub-transmission (constant mesh) 1.048 (65f62)
Transmission
Primary reduction Secondary reduction
Final reduction Sub-transmission ratio
Gearshift pattern
1.722 (31118)
Front Rear Drive Revers e Sub-transmission o (Drivel A (Reverse )
ELECTRICAL
Ignition system
Starting system
3.769 (13149 )
3.692113/48) 1.684 \32/19)
2.021 (24119 · 32f29) D- N -R 2-mode; Au t omatic and Manual (ESP; 5 speeds)
, -mode (fixed low ratio) DC-COI (Direct current-Capacitor discharge ignition) Electric starter motor and emergency recoil
starter Charging system
Regulator/rectifier Lighting system
1-6
Triple phase output alternator SeA shorted, triple phase full wave rectification Banery
GENERAL INFORMATION
LUBRICATION SYSTEM SPECIFICATIONS i ;
i i
I denum additives) 4-stroke oil and Canada). or Honda 4-stroke oil (Canada only), or an equivalent motor
oil API service classification: SG or Higher except oils labeled as energy conserving on the circular API service label JASO T 903 : MA
pressure pump rotor
FUEL SYSTEM SPECIFICATIONS
1-7
GENERAL INFORMATION
CYLINDER HEADIV ALVE/CAMSHAFT SPECIFICATIONS Unit· mm (in)
ITEM r-&~,li nder compression at 450 rpm Valve clearance Valve,
Valve stem 0.0.
valve guide Valve guide 1.0. Stem-te-guide clearance
Valve guide projection above cylinder head
rva lve seat width Valve spring Rocker arm
- Camshaft and cam follower
Free length Arm 1.0. Shaft 0 .0 . Arm-Io·shaft clearance Cam lobe height
r Cam follower 0.0. Follower bore 1.0. Follower-to-bore clearanca Cylinder head warpage
IN EX IN EX INlEX f---;N EX IN EX INlEX Inner Outer IN/EX
INfEX
INlEX IN EX INfEX INfEX INIEX
STANDARD 736 kPa (7.5 kgf/cm", 107 psi) 0.15 (0.006) 0.15 10.006) 5.475 - 5.490 (0.2156 - 0.2161) 5.455 5.470 (0.2148 0.2 154) 5.500 5.5 12 (0.2 165 - 0.2 170) 0.010 - 0.037 (0.0004 - 0.0015) 0.030 0.057 (0.0012 0.0022) 15.8 16.0 (0.62 0.63 15.8 16.0 (0.62 0.63) 1.0 - 1.1 (0.039 0.043)
SERVICE UMIT
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-
5.45 (0.2 15) 5.43 (0.2 14) 5.53 (0.218) 0. 12 (0.005) 0.14 (0.006)
-
1.4 (0.06)
37.8 (1.49)
37.04 (1.458 ~
42.7 (1.68) 12.000 12.018 (0:4724 - 0.4731) 11.964 - 11.984 (0.4710 - 0.4718) 0.016 - 0.054 (0.0006 0.0021) 35.9795 36.2195 (1.41651 1.42600) 35.9245 - 36.1654 (1.41435 -1.42383) 22.467 22.482 (0.8845 - 0.8851) 22.510 22.526 (0.8862 0.8868) 0.028 - 0.059 (0.0011 0.0023)
41.85 (1.648)
-
12.05 (O.474) 11.92 (0.46!~ 0.08 (0.003) _ 35.84 (1.411) 35.79 (1.409) 22.46 (0.884) 22.54 (0.8~P0.07 (0.003) 0.10 (0.004)
CYLINDER/PISTON SPECIFICATIONS
piston pin. piston ring
gap
CENTRIFUGAL CLUTCH SPECIFICATIONS ,r-Clutch
Unit- mm (in)
ITEM Drum 1.0. ~~ht lining thickness
Clutch spring height
r-a~tch weight spring free length Clutch drum boss 1.0. Crankshaft 0.0. at clutch drum
1-8
STANDARD 140.0 140.2 (5.51 5.52) 3.0 (0.12) 3.10 (0.122) 216 (0.85) 27.000 - 27.021 (1.0630 - 1.0638) 26.959 26.980 t1.0614 1.0622)
SERVICE UMI''':..:. :c 140.4 (5.53) 2.0 (0.08) 3.00 (0.118) 22.5 (0.89) 27.05 (1.065) 26.93 (1.060)
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GENERAL INFORMATION
ALTERNATOR/STARTER CLUTCH SPECIFICATIONS driven
boss
SUB-TRANSMISSION SPECIFICATIONS
r R,.v.c,.. idle gear
drive gear
CRANKSHAFT/AUTOMATIC TRANSMISSION SPECIFICATIONS ITEM Crankshaft
Aunout Big end side clearance Big end radial clearance
STANDARD
0.05 0 .65 (0.002 - 0.026) 0,006
0.D18 (0 .0002 - 0.0007)
Unit- mm (in) SERVICE LIMIT 0.05 (0.002) 0.8 (0.03)
0.05 (0.002)
1-9
GENERAL INFORMATION
FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS ITEM
STANDARD
Minimum tire tread depth
Standard Minimum
Cold tire pressure
25 22 28 25
SERVICE LIMIT 4.0 mm (0. 16 in)
(0.25 kgf/cm • 3.6 psi) (0.22 kgf/cm • 3.2 psi) (0.28 kgf/cm • 4.0 psi) (0.25 kgf/cm • 3.6 psi) 347.5 ± 1 mm (13.68 ± 0.4 in) Toe-out: 18 ± 15 mm (11/18 ± 9/16 in)
Maximum With ca rg o Tie-rod distance between the ball joints
To.
kPa kPa kPa kPa
REAR WHEEL/SUSPENSION SPECIFICATIONS ITEM
STANDARD
Minimum tire tread depth
SERVICE LIMIT 4.0 mm (0.16 in)
Cold tire pressure
Standard
25 22 28 25
Minimum Maximum With cargo
kPa kPa kPa kPa
(0.25 (0.22 (0.28 (0.25
kgf/cm', 3.6 kgf/cm ,3.2 kgf/cm , 4.0 kgf/cm , 3.6
psi) psi) psi) psi)
BRAKE SYSTEM SPECIFICATIONS ITEM Dcum I.D.
160.0 )6.30)
161
'-34) )
-
Bcoke pooel .
0.4 J.02)
14.0 f-O=ReaccCC:;;; bCO" C:;--
Dcum I.D. Bcoke lev", fee, pl.y
1-10
~
160.0 (6.30)
15-¥oi
161.0 (6.34)
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GENERAL INFORMATION
FRONT DRIVING MECHANISM SPECIFICATIONS
REAR DRIVING MECHANISM SPECIFICATIONS Unit' mm (in)
ITEM Rear axle
Axle runout
Final drive
Oil capacity
STANDARD
SERVICE UMlT 3.0 (0.12)
,drainin g At disassembly
h
f--" Recommended oil
85 em (2.9 US OZ, 3.0 Imp azl 100 em (3.4 US OZ, 3.5 Imp oz) Hypoid gear oil SAE #80
Gear backlash Backlash difference
0.05
Ring gear-ta-stop pin clearance
0.3
0.25 (0.002 0.6 (0.01
0.010)
0.4 (0.02) 0.2 (0.01)
0.02)
SA TTERY /CHARGING SYSTEM SPECIFICATIONS ITEM Battery
S PECIRCAnONS 12V 12 Ah 1 rnA max. 13.0-13.2 V Below 12.3 V 1.4 Ai5 10 h 6.0 All.0 h 0.32 kWI5,OOO rpm 0.1 1,On
Capacity
Current leakage Voltage (20"C/68° F) Charging current
Alternator
I- Capacity
Fully charged Needs charging Normal Quick
Charging coil resistance (20°C/68° F)
-
IGNITION SYSTEM SPECIFICATIONS
ELECTRIC STARTER SPECIFICATIONS ITEM Starter motor brush length
STANDARD
12.5 (0.49)
Unit: mm {in) SERV ICE LIMIT
9.010.35)
1-11
GENERAL INFORMATION
LIGHTS/METERS/SWITCHES SPECIFICATIONS ;~
8,'b
12V - 2115 W ,2
I
KW5'; F,,,
; ;
LEI
r- ~mel"lighl lain
I
LED,12
-iยง-A
.
13 - 15<>
1-12
GENERAL INFORMATION
STANDARD TORQUE VALUES
6 mm bolt and nut 8 mm bolt and nut
TORQUE N·m (kgf'm , Ibf.ft ) 5 (0.5, 3.6 ) 10 (1.0, 7) 22 (2.2 . 16)
10 mm bolt and nut
34 (3.5, 25)
12 mm bolt and nut
54 (5.5, 40)
FASTENER TYPE 5 mm bolt and nul
FASTENER TYPE
5 mm screw 6 mm screw 6 mm flange bolt (8 mm head; small head) 6 mm flange bolt (8 mm head; large flange) 6 mm flange bolt (10 mm head) and nut 8 mm f lange bolt and nut 10 mm flange bolt and nut
TORQUE N 'm (kgf·m . Ibf·ft) 4 (0.4, 2.9)
9 (0.9, 6.5) 10 (1.0, 7 ) 12 (1.2, 9)
12 (1.2, 9)
26 (2.7, 20) 39 (4.0, 29)
ENGINE & FRAME TORQUE VALUES • Torque specifications listed below are for important fasteners . • Others should be tightened to standard torque values listed above. NOTE: 1. Apply locking agent to the threads. 2. Apply engine oil to the threads and seating surface. 3. Apply grease to the threads and seating surface. 4. Lock nut: replace with a new one. 5. Stake. 6. Self-lock nut; replace with a new one. 7. Castle nut: tighten to the specified torque and further tighten until its grooves aligns with the cotter pin hole. 8. U-nut.
ENGINE MAINTENANCE Q'TV
ITEM
1 1 1 1 2 2
Engine oit drain bolt Engine oit filter cent er bolt T iming hole cap Spark plug Tappet adjusting hole cap Valve adjusting screw lock nut
THREAD DIA. (mml
12 20 14 12 30 6
TORQUE N 'm (kgf·m , lbf.ftl 25 (2.5, 18) 18 ( 1.8, 13) 10 (1.0, 7) 22 (2.2, 16) 20 (2.0, 14) 17 (1.7,12)
REMARKS
LUBRICATION SVSTEM ITEM
Q'TV
4 1 1
Front crankcase cover socket bolt Oil feed pipe setting cap bolt Oil pump assembly bolt
THREAD DIA.(mm)
10 20 5
TORQUE N·m (kg"m, Ibf.ft) 34 (3.5, 25) 18 ( 1.8,13) 6 (0.6, 4.3)
REMARKS
FUEl SYSTEM ITEM Ca rburetor insulator band screw Th rottle position (TP) sensor mounting screw
f-
Q'TV
THREAD DIA. (mm)
2 2
5 5
Q'TV
THREAD DIA. (mm )
4
10
1
6
TORQUE N'm (kgf'm , Ibf.ft) 4 (0.4, 2.9) 4 (0.4, 2.9)
REMARKS NOTE 1
CVLlNDER HEAOIVALVE/ CAMSHAFT ITEM Cylinder head flange cap nut Cam dlain tensioner pivot bolt
TORQUE N 'm (kgf·m. Ibf.ft) 39 (4.0, 29) 12 (1.2, 9)
REMARKS NOTE 2 NOTE 1
1-13