Updated ATV Clymer Manual
1999-2005 Honda TRX400EX Sportrax
Overland Park, KS (2/8/06) - The M454-2,
Clymer Honda TRX400EX book has been updated to the M454-3
and now covers the TRX400ex from 1999-2005 (was 1999 to
2003).
This updated book includes 323 pages, color wiring
diagrams, retails for $31.95, has an ISBN number of
0-89287-991-2 and a UPC number of 0-2418579912 2. The
model breakdown of the book is as follows:
TRX400EX Fourtrax (1999-2000)
TRX400EX Sportrax (2001-2005)
The chapter breakdown for the M454-3 is as follows:
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
INDEX
WIRING DIAGRAMS
www.clymer.com
1-800-262-1954
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